Agilent Varian DS302 Rotary Vane Vacuum Pump User`s Manual

NOTICE: This document contains references to Varian.
Please note that Varian, Inc. is now part of Agilent
Technologies. For more information, go to
www.agilent.com/chem.
vacuum technologies
DS102 1Ph
DS202 1Ph
DS302 1Ph
DS402 1Ph
DS402 3Ph
DS602 1Ph
DS602 3Ph
Dual Stage Rotary
Vane Pumps
Model 949-9315
Model 949-9320
Model 949-9325
Model 949-9330
Model 949-9331
Model 949-9335
Model 949-9336
87-900-937-01(I)
JULY 2009
(I)
MANUALE DI ISTRUZIONI
(D)
BEDIENUNGSHANDBUCH
(F)
NOTICE DE MODE D’EMPLOI
(GB) INSTRUCTION MANUAL
DS102 – DS202 – DS302
DS402 – DS602
ISTRUZIONI PER L’USO .................................................................................................... 1
GEBRAUCHSANLEITUNG ................................................................................................. 3
MODE D’EMPLOI ................................................................................................................ 5
INSTRUCTIONS FOR USE................................................................................................. 7
TECHNICAL INFORMATION .............................................................................................. 9
SECTION I .....................................................................................................................................9
TECHNICAL DESCRIPTION .........................................................................................................9
LUBRICATION ...............................................................................................................................9
VACUUM SEALS .........................................................................................................................10
GAS BALLAST VALVE ................................................................................................................10
ANTI-SUCKBACK DEVICE..........................................................................................................10
TECHNICAL DATA ......................................................................................................................14
DIMENSIONS ....................................................................................................................15
SAFETY PRECAUTIONS ............................................................................................................17
TRANSPORT AND INSTALLATION............................................................................................17
PRELIMINARY OPERATIONS ....................................................................................................17
SECTION II ..................................................................................................................................18
ELECTRICAL MOTORS ..............................................................................................................18
Single phase universal motors...........................................................................................18
Three phase universal motors ...........................................................................................20
CONNECTIONS TO THE INLET AND EXHAUST FLANGES ....................................................21
STARTING AND RUNNING THE PUMP.....................................................................................21
STOPPING THE PUMP ...............................................................................................................22
SAFETY RULES ..........................................................................................................................22
WARNING NOTES
CAUTION NOTES
 ..................................................................................................22
....................................................................................................23
MAINTENANCE ACTIONS ..........................................................................................................23
LUBRICANTS ..............................................................................................................................24
SCHEDULED MAINTENANCE CARDS ......................................................................................26
UNSCHEDULED MAINTENANCE CARDS.................................................................................31
TROUBLESHOOTING AND CORRECTIVE ACTION.................................................................61
SPARE PARTS LIST ...................................................................................................................63
ISTRUZIONI PER L’USO
INFORMAZIONI GENERALI
Questa apparecchiatura è destinata ad uso professionale. L'utilizzatore deve leggere attentamente il presente manuale di istruzioni ed ogni altra informazione addizionale fornita dalla
Varian prima dell'utilizzo dell'apparecchiatura. La Varian si ritiene sollevata da eventuali responsabilità dovute all'inosservanza
totale o parziale delle istruzioni, ad uso improprio da parte di
personale non addestrato, ad interventi non autorizzati o ad uso
contrario alle normative nazionali specifiche.
Le pompe DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph,
DS402 3Ph, DS602 1Ph e DS602 3Ph sono delle pompe rotative bistadio a palette, a tenuta in bagno d'olio, azionate da motore elettrico mono o trifase.
Queste pompe da alto vuoto sono adatte al pompaggio di gas
non corrosivi.
Nei paragrafi seguenti sono riportate tutte le informazioni necessarie a garantire la sicurezza dell'operatore durante l'utilizzo
dell'apparecchiatura. Informazioni dettagliate sono fornite nell'appendice “Technical information”.
Questo manuale utilizza le seguenti convenzioni:

INSTALLAZIONE
Non installare e/o utilizzare la pompa in ambienti esposti ad
agenti atmosferici (pioggia, gelo, neve), polveri, gas aggressivi,
in ambienti esplosivi o con elevato rischio di incendio.
Durante il funzionamento è necessario che siano rispettate le
seguenti condizioni ambientali:
− temperatura: da +12 °C a +40 °C
− umidità relativa: 0 - 95% (non condensante).
PERICOLO!
I messaggi di pericolo attirano l'attenzione dell'operatore su una
procedura o una pratica specifica che, se non eseguita in modo
corretto, potrebbe provocare gravi lesioni personali.

ATTENZIONE!
I messaggi di attenzione sono visualizzati prima di procedure
che, se non osservate, potrebbero causare danni all'apparecchiatura.
PERICOLO!
Per proteggere contro corto-circuiti o sovraccarichi, si deve installare un interruttore automatico sulla linea d’alimentazione
principale verso i dispositivi Varian, di capacità adeguata (vedere la tabella seguente):
NOTA
P/N
949-9315
949-9320
949-9325
949-9330
949-9331
949-9335
949-9336
Le note contengono informazioni importanti estrapolate dal testo.
IMMAGAZZINAMENTO
Durante il trasporto e l'immagazzinamento delle pompe non
devono essere superate le seguenti condizioni ambientali:
− temperatura: da -20 °C a +70 °C
− umidità relativa: 0 - 95% (non condensante)
110 Vac
10 A
10 A
10 A
16 A
16 A
PREPARAZIONE PER L'INSTALLAZIONE
La pompa viene fornita in un imballo protettivo speciale; se si
presentano segni di danni, che potrebbero essersi verificati durante il trasporto, contattare l'ufficio vendite locale.
Il peso dell’imballo, comprensivo della pompa, è, al massimo, di
circa 32 [Kg].
Durante l'operazione di disimballaggio, prestare particolare attenzione a non lasciar cadere la pompa e a non sottoporla ad
urti o vibrazioni.
Non disperdere l'imballo nell'ambiente. Il materiale è completamente riciclabile e risponde alla direttiva CEE 85/399 per la
tutela dell'ambiente.
220 Vac
6A
6A
6A
7.5 A
6A
7.5 A
6A
380 Vac
6A
4A
ATTENZIONE!
Prima di avviare la pompa, occorre procedere al rifornimento di
olio lubrificante, poichè la pompa viene fornita scarica.

PERICOLO!
Togliere i tappi di protezione posti sulle flange di aspirazione e
scarico prima di ogni successiva operazione. L’aria contenuta
all’interno della pompa, in caso di accensione involontaria, può
proiettarli contro l’operatore.

NOTA
La pompa non può essere danneggiata rimanendo semplicemente esposta all'atmosfera. Si consiglia comunque di mantenerla chiusa fino al momento dell'installazione sul sistema onde
evitare eventuale inquinamento da polvere.
PERICOLO!
Durante l'installazione prestare la massima attenzione che la
flangia di aspirazione sia collegata alla camera da evacuare e
che la flangia di scarico non sia tappata (vedere la figura seguente).
La pompa non deve essere usata come compressore.
La massima pressione interna al contenitore dell'olio non deve
superare 1,5 bar (abs).
L'inosservanza di queste precauzioni può causare danni alla
macchina ed all'operatore.
1/63
87-900-937-01(I)
ISTRUZIONI PER L’USO

PERICOLO!
Nel caso si debba procedere ad operazioni di manutenzione
della pompa al termine di un periodo di esercizio, è necessario
lasciarla raffreddare, poichè la temperatura esterna può superare i 60 °C.

ATTENZIONE!

Controllare che la tensione di alimentazione corrisponda a quella indicata sul cartellino del motore.
ATTENZIONE!
Nel caso di motore trifase, una inversione di polarità provoca
l'inversione del verso di rotazione della pompa, con conseguenti possibili danni di natura meccanica.
Prima di mettere la pompa in servizio effettivo è necessario, per
il raggiungimento del vuoto limite, far marciare per circa un’ora
la pompa con zavorra aperta allo scopo di eliminare l’umidità
nell’olio.
L'accensione della pompa non richiede particolari manovre; è
sufficiente collegarla all’alimentazione elettrica agendo
sull’interruttore bipolare (versione con motore monofase) o onnipolare (versione con motore trifase).
NOTA
Prima di rispedire al costruttore una pompa per riparazioni è
indispensabile compilare e far pervenire al locale ufficio vendite
la scheda "Sicurezza e Salute" allegata al presente manuale di
istruzioni. Copia della stessa deve essere inserita nell'imballo
della pompa prima della spedizione.
Qualora una pompa dovesse essere rottamata, procedere alla
sua eliminazione nel rispetto delle normative nazionali specifiche.
PERICOLO!
La pompa è progettata per operare con fluidi neutri o non corrosivi. È assolutamente vietato l'impiego con sostanze potenzialmente esplosive o infiammabili.
SMALTIMENTO
Significato del logo "WEEE" presente sulle etichette
Il simbolo qui sotto riportato applicato in ottemperanza alla direttiva CE denominata "WEEE".
Questo simbolo (valido solo per i paesi della Comunità Europea) indica che il prodotto sul quale è applicato, NON deve
essere smaltito insieme ai comuni rifiuti domestici o industriali,
ma deve essere avviato ad un sistema di raccolta differenziata.
Si invita pertanto l'utente finale a contattare il fornitore del dispositivo, sia esso la casa madre o un rivenditore, per avviare il
processo di raccolta e smaltimento, dopo opportuna verifica dei
termini e condizioni contrattuali di vendita.
Lo spegnimento della pompa non richiede particolari manovre;
è sufficiente scollegarla dall’alimentazione elettrica agendo
sull’interruttore bipolare (versione con motore monofase) o onnipolare (versione con motore trifase).
MANUTENZIONE
Il personale addetto alla condotta ed alla manutenzione della
pompa deve essere ben addestrato e deve avere un'approfondita conoscenza delle norme antinfortunistiche.

ATTENZIONE!
In fase di sostituzione di pezzi, operare con attenzione. In particolare nel caso di adozione di motore trifase, una inversione di
polarità provoca l'inversione del verso di rotazione della pompa,
con conseguenti possibili danni di natura meccanica.
USO

PERICOLO!
Non effettuare la sostituzione dell’olio subito dopo l’arresto della macchina, in quanto la temperatura dello stesso può essere
elevata.
Collegare la pompa all’alimentazione.
PERICOLO!
Escludere sempre l'alimentazione della pompa prima di compiere operazioni di manutenzione. Apporre specifici cartelli di
avvertenza: APPARECCHIATURA IN MANUTENZIONE - NON
INSERIRE L'ALIMENTAZIONE, in corrispondenza dell'interruttore di alimentazione. Al termine ripristinare i dispositivi di sicurezza.
PERICOLO!
Le alte tensioni possono causare morte al contatto. Operare
sempre con la massima cautela e secondo le norme antinfortunistiche in vigore.

PERICOLO!
Quando la macchina è alimentata prestare attenzione per la
presenza di parti in movimento e di alta tensione.
2/63
87-900-937-01(I)
GEBRAUCHSANLEITUNG
ALLGEMEINE HINWEISE
Dieses Gerät ist für den professionellen Gebrauch bestimmt.
Vor dem Gebrauch soll der Benutzer dieses Handbuch sowie
alle weiteren von Varian mitgelieferten Zusatzinformationen
genau lesen. Bei vollständiger bzw. teilweiser Nichtbeachtung
der enthaltenen Hinweise, unsachgemäßem Gebrauch durch
ungeschultes Personal, nicht autorisierten Eingriffen und
Benutzung unter Mißachtung der nationalen Bestimmungen
übernimmt Firma Varian keinerlei Haftung.
Die Pumpen DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph,
DS402 3Ph, DS602 1Ph und DS602 3Ph sind dichte
ölbadgeschmierte zweistufige Flügelzellenpumpen, die von
einem Ein- oder Dreiphasenstrommotor betätigt werden.
Diese Hochvakuumpumpen eignen sich für das Pumpen von
nicht korrosiven Gasen.
In den folgenden Abschnitten sind alle erforderlichen
Informationen für die Sicherheit des Bedieners bei der
Verwendung des Geräts aufgeführt. Detaillierte technische
Informationen sind im Anhang "Technical Information"
enthalten.
In dieser Gebrauchsanleitung werden Sicherheitshinweise
folgendermaßen hervorgehoben:

INSTALLATION
Die Pumpe darf nicht in Umgebungen installiert und/oder
benutzt werden, die ungeschützt vor Witterungsbedingungen
(Regen, Frost, Schnee), Staub und aggressiven Gasen sind
und in denen Explosions- oder erhöhte Brandgefahr besteht.
Während
des
Betriebs
sollen
die
folgenden
Umgebungsbedingungen gegeben sein:
− Temperatur: +12 °C bis +40 °C
− Relative Feuchtigkeit: 0 - 95% (niederschlagsfrei).
GEFAHR!
Die Gefahrenhinweise richten die Aufmerksamkeit des Bedieners auf eine spezielle Prozedur oder Praktik, die bei unkorrekter Ausführung schwere Personenschäden zur Folge haben
könnte.

GEFAHR!
Zum Schutz vor Kurzschlüssen oder Überlastungen, muss ein
automatischer Schalter in die Hauptspeisungsleitung zu den
Varian-Vorrichtungen installiert werden (siehe folgende Tabelle):
ACHTUNG!
Die Warnhinweise vor bestimmten Prozeduren machen den
Bediener darauf aufmerksam, daß bei Nichteinhaltung Schäden
am Gerät entstehen können.
P/N
949-9315
949-9320
949-9325
949-9330
949-9331
949-9335
949-9336
ANMERKUNG
Die Anmerkungen enthalten wichtige Informationen, die aus
dem Text hervorgehoben werden.
LAGERUNG
Während des Transports und der Lagerung der Pumpen sollen
die folgenden Umgebungsbedingungen gegeben sein:
− Temperatur: -20 °C bis +70 °C
− Relative Feuchtigkeit: 0 - 95% (niederschlagsfrei)
110 Vac
10 A
10 A
10 A
16 A
16 A
220 Vac
6A
6A
6A
7.5 A
6A
7.5 A
6A
380 Vac
6A
4A
ACHTUNG!
Die Pumpe ist vor ihrer Inbetriebnahme mit Schmieröl zu füllen,
da sie leer geliefert wird.
VOR DER INSTALLATION
Die Pumpe wird in einer speziellen Schutzverpackung geliefert.
Eventuelle Transportschäden sind der zuständigen örtlichen
Verkaufsstelle zu melden.
Das Verpackungsgewicht beträgt, einschließlich der Pumpe,
maximal 32 Kg.
Beim Auspacken ist darauf zu achten, daß die Pumpe nicht
fallengelassen oder Stößen oder Vibrationen ausgesetzt wird.
Das Verpackungsmaterial ist ordnungsgemäß zu entsorgen. Es
ist vollständig recyclebar und entspricht der EG-Richtlinie
85/399 für den Umweltschutz.

GEFAHR!
Vor Aufnahme jeglicher Arbeiten sind die Schutzkappen an den
Saug- und Druckflanschen zu entfernen. Die im Pumpeninnern
enthaltene Luft könnte diese bei unbeabsichtigter Einschaltung
gegen den Bediener schleudern.

GEFAHR!
Bei der Installation ist unbedingt darauf zu achten, dass der
Saugflansch an die zu entleerende Kammer angeschlossen ist
und der Ablassflansch nicht verschlossen ist (siehe nachstehende Abbildung).
Die Pumpe darf nicht als Verdichter verwendet werden.
Der Druck im Ölbehälter darf nicht größer als 1,5 bar (abs) sein.
Bei
Nichtbeachtung
dieser
Anweisungen
besteht
Schadensgefahr für das Gerät und die Bedienperson.
ANMERKUNG
Die Pumpe kann, wenn sie einfach der Atmosphäre ausgesetzt
ist, nicht beschädigt werden. Sie sollte jedoch bis zur
Installation an der Anlage geschlossen bleiben, um
Verunreinigungen durch Staub zu vermeiden.
3/63
87-900-937-01(I)
GEBRAUCHSANLEITUNG

GEFAHR!
Falls die Pumpe im Anschluß an den Betrieb gewartet werden
soll, ist abzuwarten, bis sie abgekühlt ist, da ihre Oberfläche
eine Temperatur von 60°C überschreiten kann.

GEFAHR!
Vor Wartungsarbeiten ist die Pumpe stets energiefrei zu
schalten. Am Netzschalter sind spezielle Warnschilder
“INSTANDHALTUNG AM GERÄT – NICHT EINSCHALTEN”
anzubringen. Nach Abschluß der Arbeiten sind die
Sicherheitseinrichtungen wieder zu aktivieren.

ACHTUNG!
Kontrollieren, daß die Versorgungsspannung mit der
Spannungsangabe auf dem Typenschild des Motors
übereinstimmt.
Die Pumpe an das Versorgungsnetz anschließen.
GEFAHR!
Keine Ölwechsel unmittelbar nach Stillsetzung des Gerätes
vornehmen, da die Öltemperatur sehr hoch sein kann.
ACHTUNG!
Bei Ersatz von Teilen ist mit Vorsicht vorzugehen.
Insbesondere bei der Version mit Dreiphasenstrommotor
bewirkt eine Polumkehrung die Umkehrung des Drehsinns der
Pumpe, was Schäden an der Mechanik zur Folge haben kann.
ACHTUNG!
Bei Dreiphasenstrommotoren bewirkt eine Polumkehrung die
Umkehrung des Drehsinns der Pumpe, was Schäden an der
Mechanik zur Folge haben kann.
ANMERKUNG
GEBRAUCH
Bevor dem Hersteller eine Pumpe zur Reparatur zurückgesandt
wird, ist das Formular “Sicherheit und Gesundheit” in der
Anlage zum vorliegenden Handbuch auszufüllen und der
lokalen Verkaufsstelle zuzustellen. Eine Kopie des Formulars
ist der Pumpenverpackung vor dem Versand beizulegen.
Vor der eigentlichen Inbetriebnahme der Pumpe ist es zur
Erreichung des Grenzvakuums erforderlich, die Pumpe
ungefähr eine Stunde mit geöffnetem Ballast laufen zu lassen,
um die Feuchtigkeit aus dem Öl zu entfernen.
Die Einschaltung der Pumpe erfordert keine speziellen Schritte,
sie braucht nur durch Betätigung des zweipoligen (Version mit
Einphasenstrommotor) oder des allpoligen Trennschalters
(Version mit Dreiphasenstrommotor) an die elektrische
Energieversorgungsquelle angeschlossen werden.

Bei eventueller Verschrottung einer Pumpe ist diese
entsprechend der einschlägigen nationalen Vorschriften zu
entsorgen.
ENTSORGUNG
Bedeutung des "WEEE" Logos auf den Etiketten
Das folgende Symbol ist in Übereinstimmung mit der EURichtlinie WEEE (Waste Electrical and Electronic Equipment)
angebracht.
Dieses Symbol (nur in den EU-Ländern gültig) zeigt an, dass
das betreffende Produkt nicht zusammen mit Haushaltsmüll
entsorgt werden darf sondern einem speziellen Sammelsystem
zugeführt werden muss.
Der Endabnehmer sollte daher den Lieferanten des Geräts d.h. die Muttergesellschaft oder den Wiederverkäufer - kontaktieren, um den Entsorgungsprozess zu starten, nachdem er die
Verkaufsbedingungen geprüft hat.
GEFAHR!
Die Pumpe ist für den Betrieb mit neutralen und nicht
korrosiven Fluiden konzipiert. Der Einsatz mit potentiell
explosions- oder feuergefährlichen Substanzen ist streng
verboten.
Die Ausschaltung der Pumpe erfordert keine speziellen
Schritte, sie braucht nur durch Betätigung des zweipoligen
(Version mit Einphasenstrommotor) oder des allpoligen
Trennschalters (Version mit Dreiphasenstrommotor) von der
elektrischen Energieversorgungsquelle getrennt zu werden.
WARTUNG
Das für den Betrieb und die Wartung zuständige Personal soll
geschult sein und über eine solide Kenntnis der
Unfallschutzvorschriften verfügen.

GEFAHR!
Hochspannungen können bei Kontakt tödliche Folgen haben.
Es ist stets mit größter Vorsicht und gemäß der geltenden
Unfallschutzvorschriften vorzugehen.

GEFAHR!
Bei eingeschaltetem Gerät ist
Hochspannungsteile zu achten.
auf
Bewegungs-
und
4/63
87-900-937-01(I)
MODE D'EMPLOI
INDICATIONS GÉNÉRALES
Cet appareillage a été conçu en vue d'une utilisation professionnelle. Il est conseillé à l'utilisateur de lire attentivement
cette notice d'instructions ainsi que toute autre indication fournie par Varian avant d'utiliser l'appareil. Varian décline par
conséquent toute responsabilité en cas de non-respect total ou
partiel des instructions fournies, d'utilisation incorrecte de la
part d'un personnel non formé, d'opérations non autorisées ou
d'un emploi contraire aux réglementations nationales spécifiques.
Les pompes DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph,
DS402 3Ph, DS602 1Ph e DS602 3Ph sont des pompes rotatives à deux stades à palettes, étanches en bain d'huile, actionnées par un moteur électrique mono ou triphasé.
Ces pompes à vide poussé sont adaptées au pompage de gaz
non corrosifs.
Les paragraphes suivants fournissent toutes les indications
nécessaires pour garantir la sécurité de l'opérateur pendant
l'utilisation de l'appareillage. Des renseignements plus détaillés
se trouvent dans l'appendice “Technical information”.
Cette notice utilise les signes conventionnels suivants:

INSTALLATION
Ne pas installer et/ou utiliser la pompe dans des milieux exposés aux agents atmosphériques (pluie, gel, neige), à des poussières, à des gaz agressifs ainsi que dans des milieux explosifs
ou à risque élevé d'incendie.
Pendant le fonctionnement, il est nécessaire de respecter les
conditions environnementales suivantes :
− Température: de +12 °C à +40 °C
− Humidité relative : 0 - 95% (non condensante).
DANGER!
Les messages de danger attirent l'attention de l'opérateur sur
une procédure ou une manœuvre spéciale dont la mauvaise
exécution risque de provoquer de graves lésions.

ATTENTION !
DANGER!
Pour protéger contre les court-circuits ou les surintensités, il
faut installer un disjoncteur automatique sur la ligne
d’alimentation principale vers les dispositifs Varian, de bonne
capacité (voir tableau ci-dessous):
Les messages d'attention apparaissent avant certaines procédures dont le non-respect peut endommager sérieusement
l'appareillage.
P/N
949-9315
949-9320
949-9325
949-9330
949-9331
949-9335
949-9336
NOTE
Les notes contiennent des renseignements importants, extrapolés du texte.
EMMAGASINAGE
Pendant le transport et l'emmagasinage des pompes, il faut
veiller à respecter les conditions environnementales suivantes :
− température: de -20 °C à +70 °C
− humidité relative: 0 - 95% (non condensante)
110 Vac
10 A
10 A
10 A
16 A
16 A
PRÉPARATION POUR L'INSTALLATION
220 Vac
6A
6A
6A
7.5 A
6A
7.5 A
6A
380 Vac
6A
4A
ATTENTION !
Avant toute utilisation de la pompe, il est impératif de procéder
à son remplissage en huile de lubrification car elle est livrée
vide.
La pompe est fournie dans un emballage de protection spécial;
si l'on constate des marques de dommages pouvant s'être produits pendant le transport, contacter aussitôt le bureau de vente
local.
Le poids total de l'emballage et de la pompe est au maximum
de 32 Kg.
Pendant l'opération d'ouverture de l'emballage, veiller tout particulièrement à ne pas laisser tomber la pompe et à ne lui faire
subir aucun choc ni aucune vibration
Ne pas jeter l'emballage dans la nature. Le matériel est entièrement recyclable et il est conforme à la directive CEE 85/399
en matière de protection de l'environnement.

DANGER!
Avant toute autre opération, retirer les bouchons de protection
placés sur les brides d'aspiration et de vidange. En cas de mise
en marche inopinée de l'appareillage, l'air contenu à l'intérieur
de la pompe peut les projeter contre l'opérateur.

NOTE
DANGER!
Pendant l'installation, faire très attention que la bride d'aspiration soit reliée à la chambre à vider et que la bride d'évacuation
ne soit pas bouchée (voir la figure ci-après).
La pompe ne doit pas être utilisée comme un compresseur.
La pression maximale à l'intérieur du réservoir d'huile ne doit
pas dépasser 1,5 bar (abs).
Le non-respect de ces précautions peut entraîner un danger
pour l'opérateur et l'endommagement de la machine.
La pompe ne peut être endommagée en restant simplement
exposée à l'atmosphère. Il est de toute façon conseillé de la
garder dans son emballage jusqu'au moment de sa mise en
fonction afin d'éviter toute pollution due à la poussière
5/63
87-900-937-01(I)
MODE D'EMPLOI

DANGER!
En cas de nécessité de procéder à des opérations de maintenance de la pompe au terme d'une période de fonctionnement,
il est indispensable de la laisser refroidir car sa température
extérieure peut être supérieure à 60°C.

ATTENTION !
Contrôler que la tension d'alimentation correspond à la tension
indiquée sur la plaquette du moteur.

ATTENTION !
En cas de moteur triphasé, une inversion de polarité provoque
l'inversion du sens de rotation de la pompe et peut entraîner
des dommages de nature mécanique
Avant la mise en service de la pompe, il est nécessaire, pour
atteindre le vide maximum, de faire fonctionner la pompe pendant environ une heure avec le reniflard ouvert afin de supprimer l'humidité de l'huile.
La mise en marche de la pompe ne requiert aucune manœuvre
particulière ; il suffit de la brancher à l'alimentation électrique et
d'agir sur l'interrupteur bipolaire (version avec moteur monophasé) ou unipolaire (version avec moteur triphasé).
NOTE
Avant de retourner une pompe au constructeur pour réparation,
il est indispensable de remplir et d'adresser au bureau local de
vente la fiche "Sécurité et Santé" jointe à la présente notice
d'instructions. Une copie de celle-ci devra être mise dans l'emballage de la pompe avant expédition.
En cas de mise au rebut de la pompe, procéder à son élimination conformément aux réglementations nationales en la matière.
DANGER!
La pompe a été conçue pour fonctionner avec des fluides neutres ou non corrosifs. L'emploi de substances potentiellement
explosives ou inflammables est strictement interdit.
MISE AU REBUT
Signification du logo "WEEE" figurant sur les étiquettes
Le symbole ci-dessous est appliqué conformément à la directive CE nommée "WEEE".
Ce symbole (uniquement valide pour les pays de la Communauté européenne) indique que le produit sur lequel il est
appliqué NE doit PAS être mis au rebut avec les ordures ménagères ou les déchets industriels ordinaires, mais passer par
un système de collecte sélective.
Après avoir vérifié les termes et conditions du contrat de vente,
l’utilisateur final est donc prié de contacter le fournisseur du
dispositif, maison mère ou revendeur, pour mettre en œuvre le
processus de collecte et mise au rebut.
L'arrêt de la pompe ne requiert aucune manœuvre particulière ;
il suffit de la débrancher de l'alimentation électrique en agissant
sur l'interrupteur bipolaire (version avec moteur monophasé) ou
unipolaire (version avec moteur triphasé).
MAINTENANCE
Le personnel chargé de la conduite et de la maintenance de la
pompe doit avoir reçu la formation nécessaire et posséder une
connaissance approfondie des normes de prévention des accidents du travail.

ATTENTION !
En phase de substitution de pièces, opérer avec le maximum
d'attention. En particulier, en cas de moteur triphasé, une inversion de polarité provoque l'inversion du sens de rotation de
la pompe et peut entraîner des dommages de nature mécanique.
UTILISATION

DANGER!
Ne pas effectuer la substitution d'huile immédiatement après
l'arrêt de la machine car la température de cette dernière peut
être élevée.
Brancher la pompe à la source d'alimentation.
DANGER!
Avant toute opération de maintenance, il est impératif de toujours couper l'alimentation de la pompe. Placer les pancartes
spécifiques d'avertissement : APPAREILLAGE EN COURS DE
MAINTENANCE – NE PAS BRANCHER L'ALIMENTATION,
près de l'interrupteur d'alimentation. Au terme des opérations
de maintenance, restaurer les dispositifs de sécurité.
DANGER!
Les hautes tensions peuvent entraîner la mort par contact. Veiller à toujours opérer avec le maximum de prudence et dans le
respect des normes de prévention des accidents du travail en
vigueur.

DANGER!
Lorsque la machine est sous alimentation, faire attention à la
présence d'organes en mouvement et de haute tension.
6/63
87-900-937-01(I)
INSTRUCTION MANUAL
GENERAL INFORMATION
This equipment is destined for use by professionals. The user
should read this instruction manual and any other additional
information supplied by Varian before operating the equipment.
Varian will not be held responsible for any events occurring due
to non-compliance, even partial, with these instructions, improper use by untrained persons, non-authorized interference
with the equipment or any action contrary to that provided for by
specific national standards.
The DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402
3Ph, DS602 1Ph and DS602 3Ph pumps are dual-stage, rotary
vane pumps oil sealed, driven by a single-phase or three-phase
electric motor.
These high vacuum pumps are suitable for pumping non corrosive gases.
The following paragraphs contain all the information necessary
to guarantee the safety of the operator when using the equipment. Detailed information is supplied in the appendix "Technical Information".
This manual uses the following standard protocol:

INSTALLATION
Do not install or use the pump in an environment exposed to
atmospheric agents (rain, snow, ice), dust, aggressive gases,
or in explosive environments or those with a high fire risk. During operation, the following environmental conditions must be
respected:
− temperature: from +12 °C to +40 °C
− relative humidity: 0 - 95% (non-condensing)
WARNING!
The warning messages are for attracting the attention of the
operator to a particular procedure or practice which, if not followed correctly, could lead to serious injury.

CAUTION
The caution messages are displayed before procedures which,
if not followed, could cause damage to the equipment.
WARNING!
Protect against short circuits and overload by installing on Varian Device electrical main line an automatic circuit breaker of
proper capacity (see table here below):
NOTE
P/N
949-9315
949-9320
949-9325
949-9330
949-9331
949-9335
949-9336
The notes contain important information taken from the text.
STORAGE
When transporting and storing the pumps, the following environmental requirements should not be exceeded:
− temperature: from -20° to +70 °C
− relative humidity: 0 - 95% (non-condensing)
PREPARATION FOR INSTALLATION
110 Vac
10 A
10 A
10 A
16 A
16 A
The pump is supplied in a special protective packing. If this
shows signs of damage which may have occurred during transport, contact your local sales office.
Total weight of the pack, including the pump, is approx. 32 Kg.
When unpacking the pump, be sure not to drop it and avoid any
kind of sudden impact or shock vibration to it.
Do not dispose of the packing materials in an unauthorized
manner. The material is 100% recyclable and complies with
EEC Directive 85/399.
220 Vac
6A
6A
6A
7.5 A
6A
7.5 A
6A
380 Vac
6A
4A
CAUTION
Before starting the pump, fill up with lubricating oil as the pump
is delivered empty.

WARNING!
Take out the protective caps on the suction and exhaust
flanges before doing anything else. In the event of an accidental start-up, the air inside the pump could violently expel the
protective caps and harm the operator.
NOTE
Normal exposure to the environment cannot damage the pump.
Nevertheless, it is advisable to keep it closed until it is installed
in the system, thus preventing any form of pollution by dust.

WARNING!
During installation, pay maximum attention that the suction
flange is connected to the vacuum chamber and the exhaust
flange is not closed (see the following figure).
The pump must not be used as a compressor.
Maximum pressure inside the oil container must not exceed 1.5
bar (abs.)
Non-observance of these precautions may be dangerous for
the machine and the operator.
7/63
87-900-937-01(I)
INSTRUCTION MANUAL

WARNING!
Always disconnect the power supply to the pump before starting maintenance work. Place a special warning signs over the
power supply breaker switch: MACHINE UNDERGOING
MAINTENANCE - DO NOT POWER ON. When finished, remove the safety warning.

WARNING!
Do not change the oil immediately after stopping the machine
as the oil temperature may still be high.
CAUTION
Check that your electrical mains voltage corresponds to that
indicated on the motor’s plate.
Connect the pump to the power supply.
CAUTION
When replacing a part, take great care. Pay special attention to
the three-phase motor, where an inversion of polarity causes
inversion of the direction of rotation of the pump with consequent possibilities of mechanical damage.
NOTE
CAUTION
Pay special attention to the three-phase motor, where an inversion of polarity causes inversion of the direction of rotation of
the pump with consequent possibilities of mechanical damage.
Before returning the pump to the constructor for repairs the
"Health and Safety" sheet attached to this instruction manual
must be filled-in and sent to the local sales office. A copy of the
sheet must be inserted in the pump package before shipping.
USE
If a pump is to be scrapped, it must be disposed of in accordance with the specific national standards.
Before being put into service, in order to reach maximum vacuum, the pump must be left running for about an hour with the
gas ballast valve open. This will eliminate any humidity from the
oil.
There are no special procedures for switching the pump on; it
needs only to be connected to the electric power by means of
the bipolar switch (version with single-phase motor) or of the
multipolar switch (version with three-phase motor).

DISPOSAL
Meaning of the "WEEE" logo found in labels
The following symbol is applied in accordance with the EC
WEEE (Waste Electrical and Electronic Equipment) Directive.
This symbol (valid only in countries of the European Community) indicates that the product it applies to must NOT be
disposed of together with ordinary domestic or industrial waste
but must be sent to a differentiated waste collection system.
The end user is therefore invited to contact the supplier of the
device, whether the Parent Company or a retailer, to initiate the
collection and disposal process after checking the contractual
terms and conditions of sale.
WARNING!
The pump is designed for operation with neutral or noncorrosive fluids. It is absolutely forbidden to use potentially explosive or flammable substances.
There are no special procedures for switching the pump off; it
needs only to be disconnected from the electric power by
means of the bipolar switch (version with single-phase motor)
or of the multipolar switch (version with three-phase motor).
MAINTENANCE
Personnel responsible for pump operation and maintenance
must be well-trained and must be aware of the accident prevention rules.

WARNING!
Death may result from contact with high voltages. Always take
extreme care and observe the accident prevention regulations
in force.

WARNING!
When machine is powered take care on account of moving
parts and high voltages.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as temperature of
the outer surface may be in excess of 60 °C.
8/63
87-900-937-01(I)
TECHNICAL INFORMATION
The pump is equipped with a special antisuckback device which automatically isolates the
vacuum system when the pump stops. This avoids
rises in pressure or oil flow in the vacuum system
while air is allowed back into the stator chambers.
SECTION I
TECHNICAL DESCRIPTION
The DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402
1Ph, DS402 3Ph, DS602 1Ph and DS602 3Ph
pumps are dual-stage, rotary vane pumps oil
sealed, driven by a single-phase or three-phase
electric motor.
The air entering the pump after the anti-suckback
device has closed prevents the oil in the casing
from filling the stator chambers.
OUTLET PORT
The inner seals are achieved by the lubricating oil,
thanks to the close machining tolerances.
INLET PORT
There is only one oil seal on the rotor shaft, the
one preventing oil from seeping out of the pump.
This seal acts on a bushing fitted onto the shaft.
Simple replacement of this seal grants the rotor a
practically unlimited life (pumps DS402 1Ph,
DS402 3Ph, DS602 1Ph, DS602 3Ph). On the
DS102 1Ph, DS202 1Ph and DS302 1Ph pumps,
this seal acts on a surface-hardened area of the
shaft guaranteeing long rotor life.
The vacuum pumps are connected directly to the
electric motor through a flexible coupling, so that
motion is transmitted even in case of poor alignment.
These vacuum pumps are suitable for pumping
non corrosive gases.
A fan fitted on the joint and housed in the pump
support produces a forced air flow over the finned
surfaces of the casing to avoid oil overheating.
The main features are:
-
all parts in direct contact with the fluid pumped
are free of copper alloys;
-
all materials are carefully selected to provide
extended life;
-
a high capacity gas ballast device allow to
pump condensable vapors;
-
LUBRICATION
The pump’s lubricating system is force-feed type.
Oil circulation is obtained by means of a gear
pump connected to the rotor shaft.
all the parts composing the pump are fully replaceable due to the close machining tolerances and to the centering obtained by using
reference pins;
The oil is drawn through a gauze filter to prevent
any foreign bodies from entering the pump.
due to its design features and low number of
gaskets, the pump requires little maintenance,
disassembly and reassemble are easy and
require minimal time.
Shunt-mounted on the delivery line is a hydraulic
piston which, besides actuating the anti-suckback
device (see ANTI-SUCKBACK DEVICE), also
regulates pressure by discharging excess oil flow
directly into the tank.
The pump works with force-feed lubrication, provided by an auxiliary gear-pump driven by the rotor
of the vacuum pump itself. This ensures proper lubrication even when pressures are close to atmospheric.
The required flow of oil under pressure passes
through ducts that are drilled in the walls of the
pump and lubricates the bushings and the inside
parts.
-
The entire pump functional block is immersed in
the oil contained in the casing. The oil
guar3antees perfect sealing of the discharge
valves, enters the pump to ensure lubrication and
sealing of the parts inside, facilitates heat dissipation and reduces pump noise.
9/63
87-900-937-01(I)
TECHNICAL INFORMATION
VACUUM SEALS
A special feature of this pump is the low number of
gaskets that are employed.
ANTI-SUCKBACK DEVICE
The pump is equipped with a special antisuckback device to avoid air pressure rises and/or
oil backflow towards the evacuated vessel when
the pump is switched off. This device has a shutter
which automatically closes the suction duct.
The seals in the circuit are obtained by means of
VITON gaskets.
The careful surface finish of the various parts of
the pump means that vacuum sealing of the functional block is ensured by the film of oil separating
metal surfaces. Sealing of the rotor shaft is guaranteed by a rotating gasket with dust-guard lip.
In this way the pump and vacuum system are
completely isolated from each other and air can
enter the pump without any risk for the vacuum
produced in the system.
The device includes some special features,
namely:
The suction flange and duct are sealed by mean of
OR gaskets.
-
drive obtained avoiding any form of contamination of the inlet duct by fluids (oil and/or air)
used to command the shutter. Thanks to this,
when the pump is started again, the pumpdown to vacuum conditions is extremely fast
as these contaminants are not present and no
degassing is therefore required;
-
suction flange maintained closed even when
the pump is idle, so that pollutants cannot enter from the environment and no oil can overflow from the pump.
GAS BALLAST VALVE
When the pump sucks in vapors, these condense
during compression and mix with the oil, forming
an emulsion (an aqueous vapor, for example) or a
solution (organic solvent vapors, for example).
A number of problems arise from this, such as the
impossibility of obtaining high vacuums, the alteration of the properties of the oil, could cause scaling
on parts of the pump.
To avoid this, during compression at the second
stage, atmospheric air is let into the pump through
an adjustable valve, or “gas ballast valve”, located
at the top of the pump.
In this way, the discharge valve of the second
stage opens through the effect of the atmospheric
air before the partial pressure of the vapor reaches
saturation point, thus preventing condensation
from occurring. The vapors are expelled mixed
with air.
10/63
87-900-937-01(I)
TECHNICAL INFORMATION
View of the pump
11/63
87-900-937-01(I)
TECHNICAL INFORMATION
Legend (cf. figure View of the pump)
N°
1
Description
Electric motor
DS 102
SR03700702
DS202
SR03700702
DS302
SR03700702
DS402
SR03700703
DS602
SR03700703
1A
Electric motor 370-450W
SR03700865
SR03700865
SR03700865
1B
Three phase electric motor
SR03700922
SR03700922
SR03700922
SR03700704
SR03700704
2
3
4
5
7
8
9
10
11
12
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
49
50
Rubber foot
Screw
Screw
Screw
Spacer
Motor support
Handle
Screw
Right sideplate
Board
Screw
Support plate
Cylindrical pin
Screw
Rubber crown
Half-joint with fan
Half-joint (pump side)
Oil-seal ring
Special screw
OR gasket
Gas Ballast Valve knob
Half-plate
Inlet screen
OR gasket
Suction flange
Anti-suckback shutter
Piston
OR gasket
Casing gasket
Inner plate
Pump support
Anti-wear bushing
OR gasket
Kei motor side
First stage vane
First stage rotor
Spring
Tongue
Second stage vane
Second stage rotor
Tie-rod
OR gasket
Bracket
Screw
Valve cover plate
Valve spring
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
(4) - (1)
SR03700219
(4) - (2)
SR03700219
(4) - (2)
SR03700219
(5) - (3)
SR03700219
(5) - (3)
SR03700219
SR03700237
(4) - (1)
SR03700237
(4) - (2)
SR03700237
(4) - (2)
SR03700237
(5) - (3)
SR03700237
(5) - (3)
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
(4) - (1)
(4) - (1)
SR03700260
(4) - (2)
(4) - (2)
SR03700260
(4) - (2)
(4) - (2)
SR03700260
(5) - (3)
(5) - (3)
SR03700362
(5) - (3)
(5) - (3)
SR03700362
SR03700370
SR03700370
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
SR8999980101 SR8999980101 SR8999980101 SR8999980301 SR8999980301
(1)
(2)
(2)
(3)
(3)
SR03700273
SR03700319
SR03700319
SR03700371
SR03700371
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
SR8999980001 SR8999980001 SR8999980001 SR8999980401 SR8999980401
(1)
(2)
(2)
(3)
(3)
SR03700269
SR03700269
SR03700269
SR03700367
SR03700367
SR03700209
SR03700308
SR03700308
SR03700335
SR03700335
(4) - (1)
(4) - (2)
(4) - (2)
(5) - (3)
(5) - (3)
(4) - (1)
(4) - (2)
12/63
(4) - (2)
(5) - (3)
(5) - (3)
87-900-937-01(I)
TECHNICAL INFORMATION
N°
51
52
53
56
57
58
59
60
61
62
63
64
Description
Valve gasket
First stage stator
Middle plate
GasBallast Valve shutter
GasBallast Valve spring
Second stage stator
Oil pump joint
Special screw
End plate
Tongue
Washer
Nut
DS 102
(4) - (1)
SR03700261
SR03700262
(4) - (1)
(4) - (1)
SR03700321
SR03700280
DS202
(4) - (2)
SR03700316
SR03700262
(4) - (2)
(4) - (2)
SR03700321
SR03700280
DS302
(4) - (2)
SR03700495
SR03700262
(4) - (2)
(4) - (2)
SR03700321
SR03700280
DS402
(5) - (3)
SR03700363
SR03700421
(5) - (3)
(5) - (3)
SR03700364
SR03700390
DS602
(5) - (3)
SR03700419
SR03700421
(5) - (3)
(5) - (3)
SR03700364
SR03700390
SR03700285
SR03700285
SR03700285
SR03700391
SR03700391
69A External oil pump gear
SR03700281
SR03700281
SR03700281
SR03700281
SR03700281
69B Internal oil pump gear
SR03700277
SR03700277
SR03700277
SR03700277
SR03700277
(4) - (1)
03.701218
SR03700256
SR03700256
(4) - (2)
03.701218
SR03700256
SR03700256
(4) - (2)
03.701218
SR03700256
SR03700256
(5) - (3)
03.701218
SR03700256
SR03700256
(5) - (3)
03.701218
SR03700256
SR03700256
03.701326
(4) - (1)
03.701326
(4) - (2)
03.701326
(4) - (2)
03.701326
(5) - (3)
03.701326
(5) - (3)
(1)
(4) - (1)
(4) - (1)
(2)
(4) - (2)
(4) - (2)
(2)
(4) - (2)
(4) - (2)
(3)
(5) - (3)
(5) - (3)
(3)
(5) - (3)
(5) - (3)
(1)
(4) - (1)
(2)
(4) - (2)
(2)
(4) - (2)
(3)
(5) - (3)
(3)
(5) - (3)
70
71
73
74
75
76
77
78
79
80
81
83
84
85
86
87
99
100
101
102
103
104
105
106
107
108
109
110
111
Oil pump cover
Screw
Plate
Filter
Casing
Exhaust flange
OR gasket
Oil fill plug
Oil drain plug
Oil drain plug gasket
Left sideplate
Spring
Filter
Flange
Sight glass
OR gasket
Special screw
Piston
Arm
Spring
OR gasket
OR gasket
Sleeve
Spring
Ring
Arm
Insert
Special washer
Screw
NOTES
(1) Part of DS 102 Major Maintenance Kit (P/N 9499380)
(2) Part of DS 202-302 Major Maintenance Kit (P/N9499381)
(3) Part of DS 402-602 Major Maintenance Kit (P/N 9499382)
(4) Part of DS 102-202-302 Minor Maintenance Kit (P/N 9499370)
(5) Part of DS 402-602 Minor Maintenance Kit (P/N 9499371)
13/63
87-900-937-01(I)
TECHNICAL INFORMATION
TECHNICAL DATA
The following table lists the main technical data of the DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph,
DS402 3Ph, DS602 1Ph and DS602 3Ph pumps.
TECHNICAL DATA
FREE AIR DISPLACEMENT
PUMPING SPEED *
Hz
UNITS
DS102
DS202
DS302
DS402
DS602
60
l/min (cfm)
114 (4)
192 (6,8)
285 (10)
410 (14,5)
605 (21,4)
160 (9,6) 237 (14,2) 342 (20,5)
540 (30,2)
3
50
l/min (m /h)
95 (5,7)
60
cfm
3,5
5,8
8,2
12,3
18,3
50
3
5
8,3
11,6
17,4
26
-4
-4
-4
m /h
-4
mbar
10
ULTIMATE TOTAL PRESSURE *
mbar
2⋅10
-3
2⋅10
-3
2⋅10
-3
2⋅10
-3
2⋅10
-3
ULTIMATE TOTAL PRESSURE WITH GAS BALLAST *
mbar
2⋅10
-2
2⋅10
-2
2⋅10
-2
1⋅10
-2
1⋅10
-2
WATER VAPOR TOLERANCE
mbar
15
15
20
30
30
g/h
60
100
160
350
550
l
0,3/0,5
0,4/0,6
0,4/0,6
0,6/1
0,6/1
0,75/0,90
0,75/0,90
0,75/0,90
0,75/0,90
WATER VAPOR CAPACITY
OIL CAPACITY min/max
10
10
10
MOTOR RATING 1ph
50/60
kW
MOTOR RATING 3ph
50/60
kW
50
rpm
1500
1500
1500
1500
1500
60
rpm
1800
1800
1800
1800
1800
OIL TEMPERATURE
°C
50
50
52
70
72
(pump operating) **
°F
122
122
126
158
162
NOMINAL ROTATION SPEED
0,45/0,55 0,45/0,55 0,45/0,55
10
-4
ULTIMATE PARTIAL PRESSURE *
Installation category
II
Pollution degree
2
OPERATING TEMPERATURE RANGE
°C
12 - 40
12 - 40
12 - 40
12 - 40
12 - 40
WEIGHT
Kg
22
24
24
36
36
lb
48
53
53
79
79
INLET FLANGE
DN
25KF
25KF
25KF
25KF
25KF
EXHAUST FLANGE
DN
25KF
25KF
25KF
25KF
25KF
- length, 1ph
mm
454
491
491
530
530
- width
mm
134
134
134
164
164
- height
mm
212
212
212
242
242
50
V
100
200-240
100
200-240
100
200-240
100
200-240
100
200-240
60
V
100-120
200-230
100-120
200-230
100-120
200-230
100-120
200-230
100-120
200-230
50
A
8,8
5,4
8,8
5,4
8,8
5,4
11,8
6,2
11,8
6,2
60
A
8,8
4,4
8,8
4,4
8,8
4,4
12,8
6,4
1,8
6,4
Dimensions (cf. also next table):
Input single phase versions ***
Nominal voltages:
Maximum currents:
*
According to PNEUROP 6602
**
At ultimate total pressure, 20 °C (68 °F) room temperature
*** For more details about the electrical motors see pages from 17 to 20
14/63
87-900-937-01(I)
TECHNICAL INFORMATION
DIMENSIONS
MODEL UNITS
DS102
DS202
DS302
DS402
DS602
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
A
B
C
D
H
L
M
N
P
R
W
30
1,18
30
1,18
30
1,18
40
1,57
40
1,57
30
1,18
30
1,18
30
1,18
40
1,57
40
1,57
35
1,38
35
1,38
35
1,38
40
1,57
40
1,57
3
0,12
3
0,12
3
0,12
6
0,24
6
0,24
212
8,3
212
8,3
212
8,3
242
9,5
242
9,5
430
16,9
467
18,4
467
18,4
541
21,3
541
21,3
250
9,8
250
9,8
250
9,8
261
10,3
261
10,3
100
3,9
100
3,9
100
3,9
130
5,1
130
5,1
105
4,1
105
4,1
105
4,1
100
3,9
100
3,9
165
6,5
205
8,1
205
8,1
230
9,1
230
9,1
132
5,2
132
5,2
132
5,2
164
6,5
164
6,5
Pump dimensions
15/63
87-900-937-01(I)
TECHNICAL INFORMATION
Typical Performance Curves
16/63
87-900-937-01(I)
TECHNICAL INFORMATION
-
SAFETY PRECAUTIONS
Always carry the pump by means of the handles provided.
-
The pump must be set in position taking the
upmost care in order to avoid accidental falls.

WARNING!
In case of a need to handle the pump after a period of operation, it must be left to cool first as the
external surface temperature may be in excess of
60 °C.
Pump off the ground. In this case, the user
must design a suitable support structure, remembering the following points:
*
the plane supporting the pump must be
perfectly horizontal;
*
the structure should be adequately rigid;
*
the relevant safety precautions should be
applied.
Note also that the pump should be attached to
the supporting structure after replacing the
rubber feet with special anti-vibration feet,
which should be screwed to the pump base
and to the supporting plane.
After taking the pump out of its packing case, you
are advised to make the following checks:
TRANSPORT AND INSTALLATION
The pumps are shipped to the customer inside
cardboard boxes.
Total weight of the pack, including the pump, is between 30 Kg. and 40 Kg. according to the different
pump models.
The case must be handled with care, using appropriate lifting equipment.
a.
Ensure that the pump has not suffered any
damage during shipping.
b.
Check that the guards are mounted correctly
(side plates, refs. 11 and 81 in fig. View of the
pump) and that there are no uncovered or
loose parts.
PRELIMINARY OPERATIONS
Before starting the pump, fill up with lubricating oil
as the pumps are delivered empty.
CAUTION
When moving the case, ensure that it is securely
bound to the lifting equipment and that the equipment is strong enough to support the weight.
NOTE
A tin of oil is included in the packing.
The pump’s working environment is a traditional
industrial environment. Naturally sites with corrosive vapors or excessive heat are best avoided.
For details on how to fill up, see Scheduled Maintenance Card 01.
Room temperature should ideally be between 12
°C and 40 °C.
CAUTION
Oil must be poured into the casing through the
special threaded plughole and NOT through the
suction line.
If the temperature is not inside this range, consult
Varian technical service for the changes required.
Setting the pump in position should be performed
as follows:
-

WARNING!
Take out the protective caps on the suction and
exhaust flanges before doing anything else. In the
event of an accidental start-up, the air inside the
pump could violently expel the protective caps and
harm the operator.
Pump laid on the ground. There are no special
instructions for this type of installation, except
that the floor should be as flat as possible and
suited to bear the weight of the pump (it
should ideally be a concrete floor) and of any
accessories mounted on it. Note that the
pump is stable on its base plate and it should
not be necessary to anchor it to the floor with
bolts and screws; also vibrations to and from
the pump are greatly reduced by the use of
rubber feet.
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87-900-937-01(I)
TECHNICAL INFORMATION
The motor has a main on/off bipolar switch.
SECTION II
ELECTRICAL MOTORS
The motor includes a thermal protection against
overloads. If the motor is switched off by this relay,
it can be started again after a few minutes.
Single phase universal motors
They are world wide motors, dual voltages and
dual frequencies, and they are in accordance with
major international standards (UL, CSA, CE). On
the table below are shown the technical specifications of the different motors.
Consult the trouble shooting section in order to
understand and remove the overload cause.
NOTE
If fuses are installed on the power line, they must
be in accordance with the table below.
CAUTION
Before connecting to the mains, check the position
of the voltage selector situated inside the electrical
box (see next paragraph).
If you start a pump at low temperature, the current
absorbed by the motors will be for several seconds
higher than the nominal one, for this reason the
fuse on the line must be of the slow-blow type.
200 to 240 V,
50/60 Hz
100 to 120 V,
50/60 Hz
Voltage selector
Motor specifications for different pumps
PUMP
DS 102
DS 202
DS 302
DS 402
DS 602
NOMINAL
VOLTAGE [V]
Hz
RPM
kW
START UP
CURRENT [A]
FULL LOAD
CURRENT [A]
MAXIMUM FUSE
RATING [A]
100
50
1450
0.45
44
8.8
10
100 to 120
60
1730
0.55
42
8.8
10
200 to 240
50
1450
0.45
27
5.4
8
200 to 230
60
1730
0.55
24
4.4
6
100
50
1450
0.75
75
11.8
16
100 to 120
60
1730
0.90
82
12.8
16
200 to 240
50
1450
0.75
43
6.2
8
200 to 230
60
1730
0.90
39
6.4
8
18/63
87-900-937-01(I)
TECHNICAL INFORMATION
To modify the voltage setting, change the position
of the voltage selector situated inside the motor
electrical box.
Single-Phase Universal Motors Voltage Setting
CAUTION
To confirm the change of the voltage setting from
High Voltage to Low Voltage, glow the orange label above the yellow label positioned on the electrical box cover.
Before connecting to the mains, check that your
electrical mains voltage corresponds to the motor
voltage setting.


WARNING!
Disconnect the motor from the mains before opening the electrical box.
WARNING!
Close the motor electrical box cover before connecting to the main.
The motors are factory set to operate at 200-240 V
(50/60 Hz) nominal voltages.
Voltage Selector
Orange label (100 to 120 V)
On/off switch
IEC 320 main socket
Motor Electrical box
19/63
87-900-937-01(I)
TECHNICAL INFORMATION
Three phase universal motors
They are world wide motors in accordance with
major international standards (UL, CSA, CE). On
the table below are shown the technical specifications of the different motors.
HIGH VOLTAGE CONNECTION
for power supply 380V to 460V
50 - 60 Hz
STAR CONNECTION
CAUTION
Before starting the pump, give a short activation to
the power switch, in order to check that the motor
turns in the direction indicated by the arrow on the
motor body. Should it rotate in the opposite direction, invert the connection of any two phases on
the motor terminals.
LOW VOLTAGE CONNECTION
for power supply of 220V to 230 V
50 - 60 Hz
DELTA CONNECTION
Electrical Connections of Three-Phase World
Wide Motors
To connect the motor to the three-phase mains,
follow the wiring diagram on the motor plate or on
the inside of the terminal strip.
Install a multipolar switch on the power line, with
contact spacing of at least 3 mm. A magnetothermal switch must be installed downstream of
this switch, tripping at 130-140 % of the nominal
current.
CONNECTION
STAR
FREQ.
[Hz]
50
NOMINAL
VOLTAGES [V]
380 to 415
POWER
[KW]
0.75
START UP
CURRENT [A]
15
CURRENT
[A]
2.6
MAX FUSE
RATING [A]
4
STAR
60
460
0.90
14
2.4
4
DELTA
50
200 to 240
0.75
26
4.4
6
DELTA
60
200 to 230
0.90
21
4.8
6
20/63
87-900-937-01(I)
TECHNICAL INFORMATION
NOTE
Application of an oil trap filter is necessary to avoid
pollution of the surrounding atmosphere by the oil
present in the exhaust duct during pump operation.
CAUTION
It is recommended to connect the pump to the
power supply through a dedicated switch on the
main electrical panel of the installation, or in proximity of the power supply connection point.
CAUTION
Before starting the pump, give a short activation to
the power switch, in order to check that the motor
turns in the direction indicated by the arrow on the
motor body. Should it rotate in the opposite direction, invert the connection of any two phases on
the motor terminals.
Never block the pump exhaust line. This would
cause overpressure in the casing with the risk of
breaking the glass window of the level indicator
and/or expelling the oil seal gasket.
STARTING AND RUNNING THE PUMP
Before being put into service, in order to reach
maximum vacuum, the pump must be left running
for about an hour with the gas ballast valve open.
This will eliminate any humidity from the oil.
One of the most effective method to verify the rotational way of the motor, it is to start the pump with
a sheet of paper on the pump inlet. If the paper is
sucked by the pump then the motor runs in the
right way.

WARNING!
The pump is designed for operation with neutral or
non-corrosive fluids. It is absolutely forbidden to
use potentially explosive or flammable substances.
CONNECTIONS TO THE INLET AND EXHAUST
FLANGES
Remove the protective caps from both flanges.
Connect the system to be evacuated to the inlet
flange, using a centering ring with OR and a locking collar.
NOTE
If the pump is started with cold oil, initially more
than normal noise will be heard; this will last for a
few minutes only until the oil reaches its working
temperature.
NOTE
For guaranteed reliable sealing, use an OR gasket
in Perbunan or Viton.
There are no special instructions for normal operation of the pump, which is delivered to you after
completion of a running-in cycle in the factory. The
maintenance operations for a pump in working
condition may be found on the Scheduled Maintenance Cards.
The inlet duct is equipped with a sieve filter preventing solid particles from entering and damaging
the pump.
NOTE
When the gases to be pumped out contain dust, it
is advisable to insert a dust filter before the inlet
flange.
If the pump is sucking in environments with liquids
or vapors, it is important to leave it to run with the
gas ballast open so as to avoid condensation of
the vapors and contamination of the lubricating oil
as a result. When there is no danger of the oil being contaminated, the gas ballast valve should be
closed to reduce the pump’s power absorption.
NOTE
When the gases to be pumped out contain large
quantities of vapor, it is advisable to include a condense separator before the inlet flange.
The gas ballast valve will prove useful in the cold
season when, due to the lower room temperatures, it takes longer for the pump to reach rated
temperature when switched on. Compression of
the air forced in by the gas ballast valve develops
heat, which in turn increases temperature of the oil
faster.
To make best use of the pump’s capacity, use only
short, straight piping, with a diameter not smaller
than that of the inlet flange.
NOTE
If rigid piping is used, it is good practice to use a
flexible joint in order to avoid undue forcing of the
connection on the pump.
NOTE
If gases without vapors are sucked in, you are advised to open the gas ballast device from time to
time in order to eliminate the traces of humidity
they contain.
The exhaust duct must be connected to a pipe that
will take away the pumped out gases.
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TECHNICAL INFORMATION
NOTE
For repetitive work cycles, with brief time intervals
in between, it is better not to stop the pump.

WARNING NOTES
a. Death may result from contact with high voltages. Always take extreme care and observe
the accident prevention regulations in force.
STOPPING THE PUMP
There are no special procedures for switching the
pump off; it needs only to be disconnected from
the electric power by means of the bipolar switch
(version with single-phase motor - see section
MODELS WITH SINGLE-PHASE UNIVERSAL
MOTORS) or of the multipolar switch (version with
three-phase motor - see section MODELS WITH
THREE-PHASE UNIVERSAL MOTORS).
When the pump is stopped, the anti-suckback device makes it possible to maintain vacuum in the
vessel connected on the inlet flange of the pump.
If the pump is expected to be stopped for a lengthy
period, or in any case if it has pumped in large
amounts of vapors, it is good practice to run it with
the gas ballast open and the inlet line closed for a
few minutes before switching off in order to limit
the risk of corrosion or scaling due to pollution of
the oil by condensed vapors.
SAFETY RULES
Personnel responsible for pump operation and
maintenance must be well-trained and must be
aware of the accident prevention rules.
b.
Always disconnect the power supply to the
pump before maintenance work. Place a special warning signs over the power supply
breaker switch: MACHINE UNDERGOING
MAINTENANCE - DO NOT POWER ON.
c.
If you are performing maintenance after the
pump has been operating for a considerable
time, allow sufficient time for it to cool as the
external surface temperature may be in excess of 60 °C.
d.
Failure to provide the pump with an earth connection may cause serious damage to operators. Always ensure that there is an earth
connection and that it complies with the standards.
e.
When cleaning the pump and its component
parts, avoid the use of flammable or toxic solvents, such as benzin, benzol, ether or alcohol. The recommendation is to use a soap and
water solution, preferably in ultrasound washing machines, taking care to dry all the
cleaned parts at temperatures under 100 °C in
order to eliminate residual moisture.
f.
Prolonged overloads or breakdowns may
cause the electric motor to overheat, and to
release noxious smoke; remove the power
immediately as a precaution and do not approach the pump at least until you have provided ventilation to drive out the smoke. Take
care not to breathe in the fumes remaining inside the pump in the course of repair work.
g.
In case of fire, do not throw water on the
pump. Switch the power off and use CO2 extinguishers.
h.
Carefully inspect the flanges to ensure that
there are no dust, oil, dirt or defects of the
mating surfaces, before making the required
connections.
i.
Ensure that all joints and couplings are locked
correctly before starting the pump again after
repair work.
j.
Do not wear any objects that may become entangled in the mechanisms and/or act as conductors (chains, bracelets, etc.).
k.
Ensure that the tools to be used are in perfect
working condition and have insulating grips,
where necessary. Check that the insulating
material of the cables and that the conductors
of the test equipment do not show any signs
of damage.
The accident prevention precautions contained in
this section must be respected at all times during
operation and maintenance of the pump to avoid
damage to operators and to the pump.
These precautions are provided in the form of
WARNING and CAUTION notes.

WARNING!
Operating procedures, technical information and
precautions which, if not respected and/or implemented correctly may cause body harm to operators.
CAUTION
Operating procedures, technical information and
precautions which, if not respected and/or implemented correctly may cause damage to the pump.
22/63
87-900-937-01(I)
TECHNICAL INFORMATION
l. Do not replace the oil immediately after stopping the machine as the oil may still be at high
temperature.
NOTE
The frequency with which repairs are performed depends on the process and presence of substances
that shorten pump life (dust, abrasives, solvents,
water, chemically aggressive substances).
m. Perform repairs in clean and, where possible,
dust-free areas. Protect all the clearances of
connection points with suitable plastic caps and
cover the machined surface areas of all parts
stripped down until they are put back on the
pump again.
The pump must be cleaned at regular intervals of
time.
CAUTION
n. Do not start the pump if the protective sideplates (refs. 11 and 81 of fig. View of the pump)
are not properly in place.
Do not clean with Alcohol the plastic or rubber
components of the pump.
CAUTION NOTES
a.
Before putting the pump back into operation
after a breakdown, inspect it and check carefully for any other signs of damage.
b.
Use only tools that are in perfect working order and specially designed for the job; use of
inappropriate or ineffective tools may cause
serious damage.
c.
Perform repairs in clean and, where possible,
dust-free areas. Protect all the clearances of
connection points with suitable plastic caps
and cover the machined surface areas of all
parts stripped down until they are put back on
the pump again.
d.
e.
f.
g.
Use only the strictly necessary amount of lubricant;
an excess of lubricating oil, like when there is
none, may sometimes compromise proper operation of the pump.
Only the recommended lubricants, or lubricating
oils with similar characteristics and known and experimented quality, should be used.
Oil changes must be made with the oil at a sufficiently high temperature, after leaving the pump to
cool for a few minutes following operation.
The drain and filler plugs must not be left open any
longer than is strictly necessary.
When performing maintenance, look out for all signals that may precede a breakdown, in particular:
Always check the lubricant and that it is properly distributed through the pump; inadequate
lubrication may damage the pump seriously.
Give the parts some form of marking as you
strip them down to ensure that you reassemble them again in the proper order.
traces of corrosion;
•
oil leaks;
•
slack joints or couplings.
Maintenance technicians must:
Check that there are no scratches or grooves
on the machined shafts, in their seats inside
the pump or on machine-ground surfaces.
Slight scratches and abrasions may be eliminated with very fine emery paper or by a little
light grinding.
Before putting a group together, always
spread a little oil over inner parts and mating
surfaces. Replace all seals with original spare
parts before reassembling components.
MAINTENANCE ACTIONS
Maintenance may be seen as the totality of all
scheduled and unscheduled maintenance work.
Maintenance includes:
•
be aware of all applicable national directives
concerning accident prevention during work
on motor-driven pumps and should know how
to apply them;
•
have read and understood all the sections on
“Safety Rules";
•
be familiar with the essential design features
and operation of the pump;
•
know how to use and consult the pump documentation;
•
be concerned about proper operation of the
pump;
•
make a note of any irregularities in operation
of the pump and take the necessary action,
where appropriate.
Use original spare parts wherever possible and
repair a broken part as best as possible on site or
send it back to the manufacturer for repairs.
1.SCHEDULED MAINTENANCE: Maintaining the
nominal state of operation.
2.UNSCHEDULED MAINTENANCE:
the nominal state of operation
•
Restoring
23/63
87-900-937-01(I)
TECHNICAL INFORMATION
For all problems arising, or to order spare parts,
refer to our service department.
The recommended lubricating oil is the Varian Rotary Vane Fluid DS19 Type. The Rotary Vane Fluid
DS19 Type is a general purpose mechanical pump
fluid specifically engineered to provide superior
performance in high speed direct drive mechanical
pumps.
Varian S.p.A. - Vacuum Technologies
Via Varian 54
10040 Leinì (Torino) - Italy
Telephone: (39) 011.9979111
Fax: (39) 011.9979344
These precisely distilled fluids (100% solvent refined neutral paraffinic oil) deliver lower base pressure capability, faster pump-down cycles, and
reduced maintenance requirements on both the
pump and the fluid.
LUBRICANTS
It will be readily understood how important adequate lubrication is to high technology pumps like
the Varian vacuum pumps. Correct use of appropriate lubricants makes a significant contribution to
achieving best performance and warding off defects.
It is absolutely necessary to continue using the lubricants initially used to fill the tank. If this is not
possible for organizational or business reasons,
use only products with the same characteristics as
the previous oils.
When handling lubricants, the following sanitary
protection measures should be observed at all
times:
•
•
Avoid prolonged, excessive or repeated contact of the skin with products for lubrication,
and also avoid directly inhaling the fumes or
vapors of such products.
CAUTION
Mineral oils and the PFPE oil are incompatible. To
change from one type to another, the pump must
be stripped down completely and all parts washed
carefully to eliminate all oil residues.
Protect the skin by wearing appropriate
clothes and equipment (e.g. special suits,
glasses or, where permitted by the safety
regulations, gloves) or by applying a special
protective product.
•
Clean the skin carefully after contact with the
lubricants by washing freely with water and
soap.
•
Apply a skin cream after washing.
•
Take off and change clothes or shoes on
which oil has been spilled.
•
Only use of lubricants of suitable quality will guarantee safe operation of the pumps.
If you expect to have to use other lubricants, first
find out if the two products are compatible. In
cases of doubt, the lubricant used up to that time
must be flushed out by way of a pump flushing
procedure.
CAUTION
To avoid the risk of contaminating the oil, absolute
cleanliness of the pump and surrounding area
must be ensured during the lubrication procedures.
Never put rags dripping with oil into the pockets of your clothes.
When disposing of waste lubricants, observe the
following environment protection regulations:
•
The lubricants risk contaminating the water
and the ground! Therefore never pour lubricating products on to the ground, into water or in
the sewage system. All violations of these
rules are liable to persecution as provided for
by law. When using lubricants always keep an
oil can nearby.
•
Take care in draining off waste oils. In disposal of these products respect all regulations
in force concerning waste oil disposal.
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TECHNICAL INFORMATION
Varian Rotary Vane Fluid DS19 Type characteristics
PROPERTY
UNIT OF
MEASURE
ROTARY VANE FLUID
DS19 Type
Vapor pressure @ 25 °C
Torr
1·10-5
Boiling point @ 0,01 torr
°C (°F)
112 (233)
Viscosity @ 40 °C
cSt (SUS)
55 (258)
Viscosity @ 100 °C
cSt (SUS)
8,1 (52,7)
Pour point
°C (°F)
-15 (5)
Flash point
°C (°F)
213 (415)
Fire point
°C (°F)
244 (472)
g/ml
0,87
Density @ 25 °C
Varian Rotary Vane Fluid DS19 Type
vapor pressure curve
Varian Rotary Vane Fluid DS19 Type
viscosity curve
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87-900-937-01(I)
TECHNICAL INFORMATION
SCHEDULED MAINTENANCE CARDS
No.
FREQUENCY
PUMP STATUS (*)
OPERATION
01
MONTHLY
R
OIL LEVEL CHECKING
02
TWICE YEARLY
S
CLEANING THE INLET FILTER
(*) R=RUNNING S=STOPPED
NOTE
When the pump is equipped with:
• a filter for dust on the inlet side
• a condensation separator on the inlet side
these items must also be maintained, by following the Manufacturer’s instructions.
NOTE
The numbers used in the drawings on the Scheduled Maintenance Cards are those used in Figure View of the
pump.
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87-900-937-01(I)
TECHNICAL INFORMATION
Card No.
Scheduled Maintenance
01
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
MONTHLY
5 min.
Time:
Type of action:
LUBRICATION
Item:
LUBRICATING OIL 949-9390
Machine status:
S
R
1
No.
Description
1 Check the oil level and top
up if necessary.
Time
5 min
Equipment
• Cleaning rags
• Liquid detergent
Materials
Oil P/N 949-9390

WARNING!
Machine powered: take care on account of moving parts and high voltages.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60°C.
27/63
87-900-937-01(I)
TECHNICAL INFORMATION
1.
Check the oil level through the sight glass: there are two clearly visible arrows indicating maximum and
minimum levels for proper pump operation.
NOTE
The amount of oil consumed depends on the type of work, particularly on the volume being evacuated and on
the frequency of the vacuum cycles.
2.
If necessary, open the pump filling plug on the top plane of the pump and add oil.
NOTE
Before starting the procedure, check that the quality and type of oil used corresponds to the indications of Table Varian Rotary Vane Fluid DS19 Type characteristics of this manual.
CAUTION
Take great care to avoid oily residues or dust from entering the pump and jeopardizing proper operation.
3.
Close the fill plug and, using cotton or other suitable material rags, clean thoroughly the outer surface of
the top plane of the pump.
CAUTION
Never mix lubricants of different brands or quality. To change from one oil to another, the pump must be
stripped down and all parts washed carefully, taking care to eliminate oil residues.
4.
Open the gas ballast valve to purify the oil.
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TECHNICAL INFORMATION
Card No.
Scheduled Maintenance
02
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
TWICE YEARLY
10 min.
Time:
Type of action:
CLEANING
Item:
INLET FILTER
Machine status:
S
R
1
No.
Description
1 Clean the suction filter.
Time
10 min.
Equipment
• Compressed air gun
Materials

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Remove the filter (26) from the inlet flange (28).
2.
Clean the filter using an aqueous solution and dry with hot air.
3.
Put the filter back in place.
CAUTION
The filter element is designed to prevent solid particles in the air from entering the inside of the pump and if it
is not working properly, serious damage could be caused the pump’s inner parts. In such cases, it may be
worthwhile installing a large surface area filter in the pump's suction line to improve effectiveness and reduce
maintenance frequency.
If the pump sucks in gases and vapors that contain large quantities of solid particles, the filter must be
checked and cleaned more often than indicated here.
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TECHNICAL INFORMATION
UNSCHEDULED MAINTENANCE CARDS
No.
SUBJECT
FREQUENCY
101
General Warnings
102
Changing the oil
Whenever necessary
103
Disassembly of oil level indicator
When damaged
104
Disassembly of anti-suckback device shutter
When damaged
105
Disassembly of electric motor and joint
When damaged
106
Disassembly of discharge valve
When damaged
107
Disassembly of oil circulating pump
When damaged
108
Disassembly of anti-suckback valve
When damaged
109
Disassembly of pump body
When damaged
110
Replacement of oil seal ring/wear bushing
When damaged
111
Disassembly of functional block rotors
When damaged
NOTE
The numbers used in the drawings on the Unscheduled Maintenance Cards are those used in Figure View of
the pump.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
101
Pump type:
Frequency:
Type of action:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
Time:
Machine status:
F
L
GENERAL WARNINGS
Item:
1.
Pump disassembly and reassembly require some basic operations and use of tools found in most workshops.
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TECHNICAL INFORMATION
NOTE
The pump’s component parts are modular and therefore fully interchangeable. Whenever parts have to replaced, please specify in the order:
-
Pump type
-
Serial number (marked on pump identification plate).
-
Reference number on the detailed diagram, name and part number as indicated on the spare parts and
accessories list (section SPARE PARTS LIST of this manual).
To simplify maintenance work, two kits have been devised.
The Gaskets Kit, containing all the gaskets recommended for substitution after disassembly of the pump and
the most commonly used removable parts.
You are advised to keep this kit in a dry room, away from heat and light (sun and UV rays) in order to prevent
hardening of the elastomer parts.
The Maintenance Kit, including, as well as the Gaskets Kit, the 1st and 2nd stage vanes and other parts that it
may be necessary to replace when overhauling the pump completely. These parts have a life of approx. two
years under conditions of normal operation.
PUMP TYPE
KIT
GASKETS KIT
GASKETS KIT
MAINTENANCE KIT
MAINTENANCE KIT
MAINTENANCE KIT
2.
DS102 1Ph
DS202 1Ph
DS302 1Ph
X
X
X
DS402 1Ph
DS402 3Ph
DS602 1Ph
DS602 3Ph
X
X
X
X
X
X
X
ORDER
CODE
949-9370
949-9371
949-9380
949-9381
949-9382
Before reassembling the pump, all parts must be cleaned thoroughly with a soap and water solution and
rinsed with demineralized water.
CAUTION
Particular care must be taken in cleaning the lubrication ducts and oil passage nozzles, which must always be
kept free of impurities.
CAUTION
Take care that the soap and water solution does not remain in the various cavities and recesses of the pump,
in the blind holes in particular.
3.
Then dry the parts, by heating where possible but without using compressed air (it generally contains polluting substances), taking care not to exceed a temperature of 80 °C.
4.
The sequence of reassembly is the inverse of the disassembly operation. Take the same precautions:
-
Spread some clean oil of the same type as used to lubricate the pump over the different parts, in particular the inner lip of the oil seal, the bushings and vanes.
-
If the oil seal has the dust-block lip, 2/3 fill the area between the two lips with ISOFLEX TOPAS
NB5051 grease.
CAUTION
Do not allow the grease into the area of the circumferential spring.
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TECHNICAL INFORMATION
-
Lock without forcing the nuts on the four tie-rods (44) connecting the parts of the pump block. Before
locking, check that all parts are touching as required.
-
Before putting the springs and shutters of the discharge valves back in, pour a little oil into the stators
through the holes in the valves.
CAUTION
Before hooking the recall spring to the anti-suckback command bar, make sure you have put the bar all the
way into the sleeve of the rotary feedthrough to avoid bending the tapered part of the bar.
NOTE
On DS102 1Ph, DS202 1Ph and DS302 1Ph pumps, fit the joint on the motor shaft after careful removal of
grease from the surfaces and application of LOCTITE 242.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
102
Pump type:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
Frequency:
AS REQUIRED
30 min.
Time:
Type of action:
CHANGING OIL
Item:
LUBRICANT 949-9390
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Varian Rotary Vane Fluid DS19 Type
(1 liter) P/N 949-9390
• Fixed wrench for oil exhaust.
• Tank to collect oil.
• Cotton (or other suitable material) rags for cleaning.
• Soap and water solution for cleaning.

WARNING!
Do not change the oil immediately after stopping the machine as the oil temperature may still be high.

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.
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TECHNICAL INFORMATION

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
NOTE
The oil has to be replaced:
1) when it has become particularly dirty due to the presence of contaminants in the environments being
evacuated;
2) when the degree of vacuum achieved by the pump is no longer satisfactory, even after running for one
hour with the gas ballast device open.
1.
Place a tank for the waste oil under the oil drain plug (79).
NOTE
You are advised to empty the pump before it cools down completely so that the oil flows out more easily.
NOTE
The pump contains up to 1 liter of oil - make sure the tank you use for the waste oil can hold this amount.
2.
Open the oil drain plug (79) slowly; let the oil flow out by opening the fill plug (78) located at the top of the
pump. In the meantime, clean the inside of the drain plug (magnetic plug).
3.
After closing the drainage hole with its plug, make the pump perform a number of turns, giving it a brief
current pulse, so as to let residual oil in the pump chambers flow out. Then drain off the residual oil again.
4.
After all the oil has been drained, close the drain plug tight; take the tank of waste oil away and clean
thoroughly, using rags of cotton or other suitable material to dry.
5.
Clean thoroughly the pourer lip of the new oil tin; pour the oil slowly into the pump through the filler plug
(78).
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TECHNICAL INFORMATION
NOTE
Monitor through the sight glass at the front of the pump that you are not exceeding the maximum oil level permitted.
CAUTION
For disposal of waste oil, it is strictly necessary to respect the currently applicable legislation on this matter.
6.
To achieve a good vacuum level again, run the pump for one hour with the gas ballast open.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
103
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
30 min.
Time:
Type of action:
DISASSEMBLY
Item:
SIGHT GLASS
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• OR gaskets
(for pumps DS102 1Ph, DS202 1Ph
and DS302 1Ph Gaskets kit p/n 949-9370)
(for pumps DS402 1Ph, DS402 3Ph, DS602 1Ph
and DS602 3Ph Gaskets kit p/n 949-9371)
• Mechanical tools
• Sight glass

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.
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TECHNICAL INFORMATION

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
1.
Drain off the oil from the pump.
NOTE
For a description of how to drain off the oil, see the Unscheduled Maintenance Card No. 102.
2.
Unscrew the securing screws (71) and disconnect the flange (85) from the casing.
3.
Take out the OR gasket (87) and the sight glass (86).
NOTE
When reassembling, replace the gaskets that you have stripped down.
CAUTION
When reassembly is complete, proceed to fill the pump with oil again following the instructions of Unscheduled Maintenance Card No. 102.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
104
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
30 min.
Time:
Type of action:
REPLACEMENT
Item:
ANTI-SUCKBACK DEVICE SHUTTER
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Shutter
• Mechanical tools

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Disconnect the flange (28) from the inlet pipe line.
2.
Remove the 6 securing screws (17) and remove the two half-plates (25) pressing the suction flange (28)
into its seat.
3.
Remove the flange (28) and take out the piston (30) with the shutter (29) of the anti-suckback device, disengage it by exerting force on arm (101). Separate the shutter (29) from the piston rod (30) simply by
pulling.
CAUTION
Be careful not to scratch the sealing surface of the shutter (29).
4.
Reassemble by proceeding in the inverse order.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
105
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
30 min.
Time:
Type of action:
REPLACEMENT
Item:
ELECTRIC MOTOR AND JOINT
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Electric motor
• Mechanical tools

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Disconnect the motor bearing plate (8) from the support (34) by removing the four screws (4).
2.
Remove the half-joint/fan (19) from the support, together with the motor (1), the plate (8) and the plate
(12) (for the DS402 1Ph, DS402 3Ph, DS602 1Ph and DS602 3Ph only).
3.
Slacken the nut blocking the half-joint (19) to the motor shaft and take it out, using leverage between the
plate (8) and the back of the joint.
4.
Remove the four screws (5) and separate the plate (8) from the motor (1).
5.
Reassemble by proceeding in the inverse order.
Extractor
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
106
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
1 hour
Time:
Type of action:
DISASSEMBLY
Item:
DISCHARGE VALVES
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Valves (Gaskets kit)
• Mechanical tools

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Drain off all the oil from the pump.
NOTE
For a description of how to drain off the oil, see the Unscheduled Maintenance Card No. 102.
2.
Disconnect the discharge flange from its piping.
3.
Remove the nuts (3) and remove the pump casing (75).
4.
Remove the securing screw (47) holding the splash guard (49) and remove it.
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TECHNICAL INFORMATION
5.
Remove the two screws (47) on the valve press-bracket (46) and remove the bracket (46), the springs
(50) and the shutters (51).
6.
Reassemble by proceeding in the inverse order.
NOTE
When reassembling, replace all the gaskets stripped down.
CAUTION
When reassembly is complete, proceed to fill the pump with oil following the instructions of Unscheduled
Maintenance Card No. 102.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
107
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
1 hour
Time:
Type of action:
DISASSEMBLY
Item:
OIL CIRCULATION PUMP 949-9390
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Oil circulating pump P/N 949-9390
• Mechanical tools

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Drain off all the oil from the pump.
NOTE
For a description of how to drain the oil from the pump, see the Unscheduled Maintenance Card No. 102.
2.
Disconnect the discharge flange from its piping.
3.
Remove the nuts (3) and remove the casing from the pump (75).
4.
Remove the three screws (71) connecting the closing plate (70) to the side and take it out.
5.
Remove the pump gear-wheels (69).
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TECHNICAL INFORMATION
NOTE
A magnet may be used to remove the gear-wheels.
6.
Reassemble by proceeding in the inverse order.
NOTE
When reassembling, replace all the gaskets you have stripped down.
CAUTION
When reassembly is complete, proceed to fill the pump with oil again following the instructions of Unscheduled Maintenance Card No. 102.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
108
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
1 hour
Time:
Type of action:
DISASSEMBLY
Item:
ANTI-SUCKBACK DEVICE
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Gaskets kit
• Mechanical

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Drain off all the oil from the pump.
NOTE
For a description of how to drain the oil, see the Unscheduled Maintenance Card No. 102.
2.
Disconnect the discharge flanges from their piping.
3.
Remove the locking nuts (3) and remove the casing (75) from the pump.
4.
Remove the securing screw (47) and remove the splash guard (49).
5.
Remove the shutter from the anti-suckback device.
NOTE
For more details on how to remove the anti-suckback device, see Unscheduled Maintenance Card No. 104.
6.
Remove the screw (102), take out the arm (101) from the rod.
7.
Release the spring (106) from the rod arm (108).
8.
Pull the rod (108) out of the rotary feedthrough (105) sleeve.
9.
Remove the two OR gaskets (104) from the rod (108) using a screwdriver, if necessary. Be careful not to
bend the rod in doing so.
10. Remove the sleeve (105) and remove it from the support (34) together with its OR gasket (103).
11. Remove the hydraulic piston (100) from its seat in the body.
12. Reassemble by proceeding in the inverse order.
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TECHNICAL INFORMATION
NOTE
When reassembling, replace all the gaskets stripped down.
CAUTION
When reassembly is complete, proceed to fill the pump with oil again following the instructions of Unscheduled Maintenance Card No. 102.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
109
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
1 hour
Time:
Type of action:
DISASSEMBLY
Item:
PUMP BODY
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Gaskets kit
• Mechanical tools

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Drain off all the oil from the pump.
NOTE
For a description of how to drain off the oil, see the Unscheduled Maintenance Card No. 102.
2.
Disconnect the discharge flange from its piping.
3.
Disconnect the electric motor (1) complete with half-joint.
NOTE
For a description of how to disassemble the electric motor, see the Unscheduled Maintenance Card No. 105.
4.
(On DS402 1Ph, DS402 3Ph, DS602 1Ph and DS602 3Ph: remove the screw (111) and remove the seal
(110)). Slacken the nut locking the half-joint (20) to the shaft of the rotor (39) and take out the half-joint.
Remove the tongue (37) with it as well.
5.
Unscrew the securing screw (47) and remove the valve screen (49).
6.
Slacken the four nuts (64) and take out the tie-rods (44) and the complete functional block (76), lifting it
from the pump support (34) and take out the OR gaskets (27) and (45), from the gas ballast line and suction line respectively.
CAUTION
Be careful not to cut the lip of the oil seal with the sharp edges of the shaft key seat.
7.
Reassemble by proceeding in the inverse order.
NOTE
When reassembling, replace all the gaskets stripped down.
CAUTION
When reassembly is complete, proceed to fill the pump with oil again following the instructions of Unscheduled Maintenance Card No. 102.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
110
Pump type:
DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
Frequency:
WHEN DAMAGED
Time:
1 hour and 15 min.
Type of action:
REPLACEMENT
Item:
OIL SHAFT SEAL / ANTI-WEAR BUSHING
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Oil shaft seal
• Anti-wear bushing
• Gaskets kit
• Mechanical tools

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
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TECHNICAL INFORMATION
1.
Drain off all the oil from the pump.
NOTE
For a description of how to drain off the oil, see the Unscheduled Maintenance Card No. 102.
2.
Separate the functional block from the pump support.
NOTE
For a description of how to separate the functional block from the support, see the Unscheduled Maintenance
Card No. 109.
3.
Remove the worn out oil shaft seal (21) from the pump support (34) using a screwdriver for leverage and
taking care not to scratch the seat.
4.
Take the anti-wear bushing (35) off the shaft and take out the OR Gasket (36).
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TECHNICAL INFORMATION
NOTE
For assembly of the new oil shaft seal, a special tool is needed.
5.
After applying silicone grease to the external diameter of the oil seal, engage it on the tool and push it into
its seat.
6.
Reassemble by proceeding in the inverse order.
NOTE
When reassembling, replace all the gaskets stripped down.
CAUTION
When reassembly is complete, proceed to fill the pump with oil again following the instructions of Unscheduled Maintenance Card No. 102.
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TECHNICAL INFORMATION
Card No.
Unscheduled Maintenance
111
Pump type:
Frequency:
DS102 1Ph, DS202 1Ph, DS302 1Ph, DS402 1Ph, DS402 3Ph, DS602 1Ph, DS602 3Ph
WHEN DAMAGED
2 hours
Time:
Type of action:
DISASSEMBLY
Item:
FUNCTIONAL BLOCK ROTORS
Machine status:
S
R
ACTION AREA
Materials required:
Equipment required:
• Oil shaft seal ring
• Anti-wear bushing
• OR gaskets
• 1st stage vanes
• 2nd stage vanes
• Gas Ballast shutter
(the above items of material are included in
the Major Maintenance kit)
• Mechanical tools
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TECHNICAL INFORMATION

WARNING!
Machine safety: disconnect all power lines. Hang the card “MACHINE UNDERGOING MAINTENANCE - DO
NOT POWER ON” from the main breaker switch. When finished, remove the safety warning.

WARNING!
If you have to perform maintenance on the pump after a considerable time in operation, leave it to cool as
temperature of the outer surface may be in excess of 60 °C.
1.
Drain off all the oil from the pump.
NOTE
For a description of how to drain the oil from the pump, see the Unscheduled Maintenance Card No. 102.
2.
Detach the entire functional block from the pump support.
NOTE
For a description of how to detach the functional block, see the Unscheduled Maintenance Card No. 109.
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TECHNICAL INFORMATION
3.
Disassemble the discharge valves.
NOTE
For a description of how to disassemble the discharge valves, see the Unscheduled Maintenance Card No.
106.
4.
Detach the end plate (61) from the rest of the pump body, exerting leverage if necessary on the reference
notches between the parts. This will give you access to the retaining valve (56) and associated spring
(57) at the gas ballast inlet.
5.
Disconnect the 2nd stage stator (58), remove the two vanes (42), take the 2nd stage rotor (43) off the
shaft and take out the key (41).
6.
Remove the partition wall (53) from between the 1st and 2nd stages.
7.
Detach the 1st stage stator (52) from the inner side (33), pressing back on the springs (40) of the vanes
(38) to avoid the vanes from touching against the sharp corners of the body and becoming damaged.
8.
Take out the 1st stage rotor (39), the vanes (38) and the springs (40).
9.
Reassemble by proceeding in the inverse order.
NOTE
When reassembling, replace all the gaskets stripped down.
CAUTION
After reassembly is complete, proceed to fill the pump again with oil following the instructions of Unscheduled
Maintenance Card No. 102.
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TECHNICAL INFORMATION
TROUBLESHOOTING AND CORRECTIVE ACTION
NOTE
If the pump breaks down or does not work well, first check thoroughly that all the standards rules listed in the
sections relevant installation and operation are currently observed.
If you cannot get sufficiently low pressure, the problem may lie with the system connected to the pump, i.e.
the vacuum chamber and inlet line.
Even when the design sizes are correct, the problems listed below are still fairly frequent:
a) faulty seals: check that the seals are fitted, are in good working order
and are clean; check all
joints, taps, sight glasses, weld joints, etc.
b) unsuitable materials: avoid the use of rubber, plastic or even metal parts that are porous or permeable.
c) volatile substances: as far as possible, eliminate humidity, grease, dirt, rust, solvents (even small traces).
SYMPTOM
1
2
3
4
5
The pump does not start (or
stops immediately).
The pump stops (stalls).
The pump overheats.
Too much oil drained off by the
exhaust.
The pump is loosing oil.
PROBABLE CAUSE
SUGGESTED REMEDY
CARD
REF.
A) The motor-pump coupling is
defective.
Check state of the elastic joint and replace
the parts as needed.
105
B) Viscosity of the oil has increased.
Examine the oil and change if necessary
(find out why it has deteriorated).
102
C) Excessive friction inside
pump.
Test the resistance to rotation, by turning
the joint by hand. If the rotors are blocked,
disassemble the pump body and check
state of the parts inside.
111
D) Electrical protections not set.
Adjust the protections.
E) Oil too viscous because of
low room temperature.
Heat the oil up to a temperature of 20 °C
or use an oil recommended for low temperatures.
F) Direction of rotation inverted
(only 3-phase motors).
Change over two phase wires of the electric power supply.
A) Seizure of some internal
parts.
Proceed as at 1-C.
B) Oil very dirty.
Proceed as at 1-B.
A) Too much friction inside.
Proceed as at 1-C.
B) Oil ducts clogged inside.
Try changing the oil, otherwise disassemble the pump and clean it well.
102
111
A) Gas Ballast device broken
(always open).
Check the device to ensure the gas ballast
is properly adjusted.
111
B) Heavy duty work (high suction pressures or very frequent
cycles).
Check condition of the oil trap filter.
C) Leak in system.
Check the system (see “Note”).
A) Seal on shaft defective.
Replace the oil seal and the anti-wear
bushing.
B) Other gaskets defective.
Identify the areas where seeping occurs
and check the associated gaskets.
C) Oil level window broken
Replace the oil level window.
61/63
102
110
Refer to the
card related
to involved
item
87-900-937-01(I)
TECHNICAL INFORMATION
SYMPTOM
6
7
8
The pump is very noisy even at
steady operating conditions.
When the pump is stopped, the
inlet pressure rises rapidly.
The pump does not produce a
sufficient vacuum.
PROBABLE CAUSE
SUGGESTED REMEDY
CARD
REF.
A) Exhaust valves damaged.
Inspect the valves.
B) High suction pressure, or gas
ballast device is open.
Check the system and the gas ballast
valve (see items 4-A and 4-B).
C) Elastic star of joint is damaged.
Check and replace if necessary.
D) A screw of the joint has become loose.
Lock the screw after application of Loctite
222 (for slack threads).
A) The anti-suckback device is
defective.
Disassemble and check the anti-suckback
device.
B) The cause of the problem is
not with the pump.
See “Note”.
A) Not enough oil, or oil contaminated.
Check level and appearance of the oil.
Open the Gas Ballast for half an hour at
least; change the oil whenever necessary.
B) Oil ducts clogged inside.
Proceed as at 3-B.
C) Direction of rotation inverted.
Proceed as at 3-C.
D) OR gaskets communicating
with the inlet line defective.
Replace the gaskets.
E) Exhaust valves damaged or
out of place.
Proceed as at 6-A.
F) Insufficient oil pressure in the
lubricating circuit, preventing the
anti-suckback device from
opening.
Inspect the gears of the oil pump and
check that it is working.
107
G) Internal moving parts worn.
Disassemble the pump, and replace any
worn parts.
111
H) Pump working with gas ballast device open.
Close the gas ballast device.
I) Anti-suckback valve fails to
open.
Disassemble the suction flange and check
the device.
104
108
J) Parts of the functional block
not in perfect contact because
of deposits of dirt or failure to
put a plug on the service holes.
Disassemble and check condition of the
part surfaces and that plugs have been
used.
111
K) The cause of the problem is
not with the pump.
See “Note”.
62/63
106
108
01
102
109
87-900-937-01(I)
TECHNICAL INFORMATION
SPARE PARTS LIST
OTHER SPARE
PARTS
MINOR MAINTENANCE KIT (*)
Q.TY
DS102 1Ph DS202 1Ph DS302 1Ph
X
X
DS402 1Ph DS602 1Ph
DS402 3Ph DS602 3Ph
X
949-9370
MINOR MAINTENANCE KIT (*)
MAJOR MAINTENANCE KIT (**)
X
X
949-9371
X
MAJOR MAINTENANCE KIT (**)
P/N
949-9380
X
X
949-9381
MAJOR MAINTENANCE KIT (**)
X
X
949-9382
Q.TY
ACCESSORY ITEM
DS402 1Ph DS602 1Ph
ON EXHAUST
DS102 1Ph DS202 1Ph DS302 1Ph
DS402 3Ph DS602 3Ph
P/N
OIL MIST ELIMINATOR KF25
X
X
X
X
X
949-9395
OIL MIST CARTRIDGE (Q.ty 2)
X
X
X
X
X
949-9394
RECOMMENDED OIL
P/N
Q.TY
Varian Rotary Vane Fluid DS19 Type (Europe)
949-9390
1 liter
Varian Rotary Vane Fluid DS19 Type (USA)
K7516301
1 liter
Varian Rotary Vane Fluid DS19 Type (USA)
K7516302
1 gallon
(*) Contains all the valves, O-rings and seals to refurbish the pump to vacuum integrity.
(**) Includes all the items of the minor maintenance kit plus the vanes.
63/63
87-900-937-01(I)
Request for Return
1.
2.
3.
4.
A Return Authorization Number (RA#) WILL NOT be issued until this Request for Return is completely filled out,
signed and returned to Varian Customer Service.
Return shipments shall be made in compliance with local and international Shipping Regulations (IATA, DOT, UN).
The customer is expected to take the following actions to ensure the Safety of workers at Varian: (a) Drain any oils or
other liquids, (b) Purge or flush all gasses, (c) Wipe off any excess residues in or on the equipment, (d) Package the
equipment to prevent shipping damage, (for Advance Exchanges please use packing material from replacement unit).
Make sure the shipping documents clearly show the RA# and then return the package to the Varian location nearest you.
North and South America
Varian Vacuum Technologies
121 Hartwell Ave
Lexington, MA 02421
Phone : +1 781 8617200
Fax: +1 781 8609252
Europe and Middle East
Varian SpA
Via Flli Varian 54
10040 Leini (TO) – ITALY
Phone: +39 011 9979111
Fax: +39 011 9979330
Asia and ROW
Varian Vacuum Technologies
Local Office
CUSTOMER INFORMATION
Company name: ..………………….……..……………….………………………………..……………………...…………..….
Contact person: Name: ……………………………………..…
Tel: ……………………….…...…………….….…....
Fax: …………………………….…...…..……
E-Mail: ..……………………..…………..…..…..…..
Ship Method: …………….……....…… Shipping Collect #: ………….…..………… P.O.#: ………………….…......………..
Europe only: VAT reg. Number: ………………..……………...
Customer Ship To: ………………………….………
……………..…………………...
………………..………………...
PRODUCT IDENTIFICATION
Product Description
USA only:
Taxable
Non-taxable
Customer Bill To: …………………..……………...
..………………………………...
..………………………………...
Varian P/N
Varian S/N
TYPE OF RETURN (check appropriate box)
Paid Exchange
Paid Repair
Warranty Exchange
Credit
Shipping Error
Evaluation Return
Warranty Repair
Calibration
Purchase Reference
Loaner Return
Other ……………….
HEALTH and SAFETY CERTIFICATION
Varian Vacuum Technologies CAN NOT ACCEPT any equipment which contains BIOLOGICAL HAZARDS or
RADIOACTIVITY. Call Varian Customer Service to discuss alternatives if this requirement presents a problem.
The equipment listed above (check one):
HAS NOT been exposed to any toxic or hazardous materials
OR
HAS been exposed to any toxic or hazardous materials. In case of this selection, check boxes for any materials that
equipment was exposed to, check all categories that apply:
Toxic
Corrosive
Reactive
Flammable
Explosive
Biological
Radioactive
List all toxic or hazardous materials. Include product name, chemical name and chemical symbol or formula.
.……………………………………………………………………………………………………………………..
Print Name: ………………………………….
Customer Authorized Signature: ……………...…………………….
Print Title: …………………………………...
Date: ..…../..…../……
NOTE: If a product is received at Varian which is contaminated with a toxic or hazardous material that was not disclosed, the customer
will be held responsible for all costs incurred to ensure the safe handling of the product, and is liable for any harm or injury to Varian
employees as well as to any third party occurring as a result of exposure to toxic or hazardous materials present in the product.
Do not write below this line
Notification (RA)#: ……………………….……….. Customer ID#: ……….…………. Equipment #: ……………………..
Request for Return
FAILURE REPORT
TURBO PUMPS and TURBOCONTROLLERS
Does not start
Does not spin freely
Does not reach full speed
Mechanical Contact
Cooling defective
TURBOCONTROLLER ERROR
Noise
Vibrations
Leak
Overtemperature
POSITION
Vertical
Horizontal
Upside-down
Other:
………………….
PARAMETERS
Power:
Rotational Speed:
Current:
Inlet Pressure:
Temp 1:
Foreline Pressure:
Temp 2:
Purge flow:
OPERATION TIME:
MESSAGE:
ION PUMPS/CONTROLLERS
Bad feedthrough
Poor vacuum
Vacuum leak
High voltage problem
Error code on display
Other
Customer application:
VALVES/COMPONENTS
Main seal leak
Solenoid failure
Damaged sealing area
Customer application:
Bellows leak
Damaged flange
Other
LEAK DETECTORS
Cannot calibrate
Vacuum system unstable
Failed to start
Customer application:
No zero/high backround
Cannot reach test mode
Other
INSTRUMENTS
Gauge tube not working
Communication failure
Error code on display
Customer application:
Display problem
Degas not working
Other
PRIMARY PUMPS
Pump doesn’t start
Doesn’t reach vacuum
Pump seized
Customer application:
Noisy pump (describe)
Over temperature
Other
DIFFUSION PUMPS
Heater failure
Doesn’t reach vacuum
Vacuum leak
Customer application:
Electrical problem
Cooling coil damage
Other
FAILURE DESCRIPTION
(Please describe in detail the nature of the malfunction to assist us in performing failure analysis):
NOTA: Su richiesta questo documento è disponibile anche in Tedesco, Italiano e Francese.
REMARQUE : Sur demande ce document est également disponible en allemand, italien et français.
HINWEIS: Auf Aufrage ist diese Unterlage auch auf Deutsch, Italienisch und Französisch erhältlich.
Sales and Service Offices
United States and Canada
Varian, Inc.
Japan
Varian Technologies Japan, Ltd.
121 Hartwell Avenue
Lexington, MA 02421
USA
Tel.: +1 781 861 7200
Fax: +1 781 860 5437
Toll-Free: +1 800 882 7426
Sumitomo Shibaura Building, 8th Floor
4-16-36 Shibaura Minato-ku
Tokyo 108, Japan
Tel.: +81 3 5232 1253
Fax: +81 3 5232 1710
Toll-Free: 0120 655 040
Benelux
Varian Vacuum Technologies
Korea
Varian Technologies Korea, Ltd.
Herculesweg 8
4338 PL Middelburg
The Netherlands
Tel.: +31 118 671570
Fax: +31 118 671569
Shinsa 2nd Bldg. 2F, 966-5 Daechi-dong
Kangnam-gu, Seoul
Korea 135-280
Tel.: +82 2 3452 2452
Fax: +82 2 3452 2451
Toll-Free: 080 222 2452
China
Varian Technologies China, Ltd.
Mexico
Varian, S. de R.L. de C.V.
Rm 1648 Central Tower South Wing
Beijing Junefield Plaza
No. 10 XuanWuMenWai Street
Beijing 100052, P.R. China
Tel.: +86 (10) 6310 8550
Fax: +86 (10) 6310 0141
Toll-Free: 800 820 6556
Concepcion Beistegui No 109
Col Del Valle
C.P. 03100
Mexico, D.F.
Tel.: +52 5 523 9465
Fax: +52 5 523 9472
France
Varian s.a.
South East Asia
Varian Vacuum Technologies
7 Avenue des Tropiques
Z.A. de Courtaboeuf - B.P. 12
Les Ulis cedex (Orsay) 91941 France
Tel: +33 1 69 86 38 84
Fax: +33 1 69 86 29 88
South East Asia (SEA)
Tel.: +601 2213 1253
Fax: +603 6733 8121
Germany and Austria
Varian Deutschland GmbH
Alsfelder Strasse 6
Postfach 11 14 35
64289 Darmstadt
Germany
Tel: +49 6151 703 353
Fax: +49 6151 703 302
Other Countries
Varian S.p.A.
Vacuum Technologies
Via F.lli Varian, 54
10040 Leinì (Torino)
Italy
Tel: +39 011 997 9111
Fax: +39 011 997 9350
Customer Support & Service:
North America
Toll-Free: 1 800 882 7426
[email protected]
Europe
Toll-Free: 00 800 234 234 00
[email protected]
China
Toll-Free: 800 820 8266
[email protected]
Japan
Toll-Free: 0120 655 040
[email protected]
Korea
Singapore
Varian Vacuum Technologies
Singapore
Unit 10-04 Helios
Biopolis @ one-north
11 Biopolis Way, 138667 Singapore
Tel.: +65 92364988
Fax: +65 64789603
Toll-Free: 080 222 2452
[email protected]
Taiwan
Toll-Free: 0 800 051 342
[email protected]
Taiwan
Varian Technologies Asia Ltd.
Worldwide Web Site, Catalog
and Order On-line:
205-A, “A” wing of Galleria,
2nd floor, Hiranandani Gardens,
Powai, Mumbai-400 076, India
Tel.: +91 22-2570 8595 / 8597
Fax: +91 22- 2570 8599
14F-6, No.77, Hsin Tai Wu Rd., Sec. 1
Hsi chih, Taipei Hsien
Taiwan, R.O.C.
Tel.: +886 2 2698 9555
Fax: +886 2 2698 9678
Toll Free: 0800 051 342
www.varianinc.com
Italy
Varian S.p.A.
UK and Ireland
Varian Ltd.
India
Varian India PVT Ltd.
Via F.lli Varian, 54
10040 Leinì (Torino)
Italy
Tel: +39 011 997 9111
Fax: +39 011 997 9350
02/09
6 Mead Road
Oxford Industrial Park - Yarnton
Oxford OX5 1QU - England
Tel.: +44 (0) 1865 291570
Fax: +44 (0) 1865 291571
Representative in most countries